Z4INSTALLATION & OPERATION WORKBOOK Inc. permanent injury or death. Contact Zodiac Pool Stsyems. • Keep all electrical equipment at least 10 feet (3m) from inside wall of pool or spa. ordinances. do not attempt any of the electrical repairs presented in this document. at 1-800-822-7933 for assistance. handle or play on equipment.IMPORTANT SAFETY INSTRUCTIONS The information contained in this technical guide is intended for Zodiac trained service personnel only.). Failure to heed the following warnings could result in property ! WARNING damage. When servicing equipment. TO REDUCE EQUIPMENT WATER PRESSURE HAZARD: • Always turn pump off to release pressure prior to removing or installing in-line equipment. do not permit children to operate. do not exceed water pressure (psi) specifications for the device. • Use only copper conductors and supply wires suitable for the specific device. state and local law. Read and follow all instructions carefully. • Do not install or service equipment if precipitation is present or imminent. • Replace damaged power cord(s) immediately and use only identical replacement parts. If you have not received training. etc. • To avoid equipment damage. codes and regulations. • Do not bury power cord(s). Position cord(s) to minimize abuse from lawn mowers. and must comply with all national electric codes (NEC. 3 . hedge trimmers and other equipment. Canadian. Electrical installation and repairs should only be performed by a certified electrician or Zodiac trained professional. basic safety precautions should always be followed including those listed below. TO REDUCE THE RISK OF ELECTRICAL SHOCK: • Disconnect main power to pool equipment area prior to any service or repairs. • Connect equipment only to a receptacle (cord models) or circuit (hardwired) protected by a ground fault circuit interrupter (GFCI). To reduce the risk of injury. Inc.ZodiacPoolSystems.Zodiac® Pool Systems.com Instructor: __________________________________________________ ext.academy@zodiac. _______ Notes: 4 . _______ Sales person: ________________________________________________ ext.com Regional Extension_________________ www. Zodiac Academy 1-800-822-7933 zodiac.trainyu.com/zodiac www. _______ Service Manager: ____________________________________________ ext. .................................................................................................10 AQUALINK® WIRELESS REMOTE (AQUAPALM™) ...........................................LXi or LRZE) .11 iAQUALINK™............8 TWO SPEED RELAY WIRING ............. 7 INSTALLATION 3 HP RELAY WIRING .... 17 ................................................................................................................15 & 16 HEATER CONNECTION (T-STAT .............................20 & 21 POOL ONLY ...14 MENU HEATER CONNECTION (SMART ............................................................... 6 COMPONENTS .........................................................................................................................................................................................................12 MULTIPLEX BOARD......................................6 USER INTERFACE ................................... TABLE OFOFCONTENTS TABLE CONTENTS TABLE OF CONTENTS FINISH GOODS PART NUMBERS and MODELS ............................................................. 22 & 23 5 ........................................................................................................................................................................... 9 SENSORS ....................................................................................LXi™) .......12 JVAs .................................................13 HEATER CONNECTION (GENERIC) .................................................................19 POOL AND SPA COMBINATION ............ The 3 volt lithium battery keeps the clock running during a power outage. MODELS MODELS AND SERIAL NUMBER Models Pool Pool & Spa iAquaLink Only Combo ZQ-4PS X ZQ-4PSi X X ZQ-4P X ZQ-4Pi X X FUNSB1308465 Serial Number Z4 (US Market) Month of manufacture (A=Jan. C=March. then remove the four screws. To access the battery open the power center door. B=Feb. remove the two screws holding the User Interface in place. 6 . If a power outage occurs the user inputs will not be lost even if the battery is dead. etc) Year of manufacture Unit manufactured in that month USER INTERFACE (UI) LAYOUT Display Screen Scroll Up and Zodiac Down Buttons Air 72 F Pool Mode Off Pool Heater Off Aux1 Off Aux2 Off Settings > Devices > Back Button Select Button Alert LED Power Alert Power ON LED Power ® Button Off/ON AquaLink® Z4 MEMORY AND BATTERY BACKUP All user inputs are stored at the User Interface. . 60 Hz. Grn Yel Blk Red INTAKE RETURN SOLAR FIL_PMP AUX 1 AUX 2 AUX 3 JVA Sockets Relay Sockets 1 2 3 4 5 6 7 8 9 10 24 VAC 24 VDC Low Volt Water Spare Heater Sensor Input Solar Air/Freeze Sensor Sensor 7 .15 amp fuse Connector. • Maximum 1500 Watts per contact PRINTED CIRCUIT BOARD (PCB) COMPONENTS RS 485 connection User Interface 3. 24 VAC Printed Circuit Board (PCB) Grn Yel Blk Red INTAKE RE TURN S OLAR FIL_PMP AUX 1 AUX 2 AUX 3 Grounding Bar 3 HP Relays Coil (input) – 24 VDC Contacts: Double Pole Single Throw (DPST) • Maximum 3 horsepower motor when wired for 230 VAC • Maximum 1. COMPONENTS POWER CENTER COMPONENTS Transformer Primary: 120 VAC. Secondary: Class 2. 3 amp.5 horsepower motor when wired for 115 VAC. INSTALLATION .5 horsepower when wired 120 VAC 1500 Watts per contact COIL WIRES 24 VDC LINE 1 LOAD 2 LOAD 1 LINE 2 3 HP RELAY WIRING Contacts 240 VAC wiring shown Grn Yel Blk Red INTAKE RETURN SOLAR FIL_PMP AUX 1 AUX 2 AUX 3 8 . Measure resistance with coil Coil (input): 24 VDC wire disconnected from the PCB.R0658100 and 400 Ohms. 1. Contacts: 3 horsepower when wired 240 VAC A shorted relay coil can damage the PCB.RELAYS WIRING 3 HP RELAY Relay coil resistance must be between 300 P/N . of relay to High Speed of Motor Connect to Common of Motor NOTES: 9 . INSTALLATION . Normally Normally 24 VDC Open (NO) Closed (NC) 2 SPEED RELAY WIRING 240 VAC wiring shown Grn Yel Blk Red INTAKE RETURN SOLAR FIL_PMP AUX 1 AUX 2 AUX 3 C .C. of relay to Low Speed of Motor Connect from N.O.6796 Coil: 24 VDC Common Contacts: 2 horsepower when wired 240 VAC 1 horsepower when wired 120 VAC Setup and Programming In Settings go to Filter Pump and chose Two Speed Pump.Common Connect from N.RELAYS WIRING 2 SPEED RELAY P/N . • Avoid splicing sensor wires. SENSOR LOCATIONS Solar Panels Solar Sensor HOT CHAUD Water Sensor SENSORS WIRING Grn Yel Blk Red INTAKE RETURN SOLAR FIL_PMP AUX 1 AUX 2 AUX 3 1 2 3 4 5 6 7 8 9 10 Sensor Connections Water Air – 7 & 8 Sensor Water – 5 & 6 Solar – 3 & 4 Solar Air/Freeze Sensor Sensor 10 . Air Temperature Sensor • The Air Sensor comes factory installed to the bottom of the Power Center. INSTALLATION - SENSORS SENSORS Water Temperature Sensor • With the filter pump off drill a 3/8 inch (10 mm) hole in the pipe between the filter pump and filter. Solar Temperature Sensor • Mount the solar sensor (if applicable) next to the solar panels exposed to the same sun light. • Make certain the “O” ring is in place on the sensor housing. • This sensor activates freeze protection when the air temperature reaches approximately 38 F. • Insert the sensor in the hole and clamp in place. AQPLM Install the AquaLink Wireless Remote per the installation manual. INSTALLATION - AQUALINK® WIRELESS REMOTE AQUALINK WIRELESS REMOTE (AquaPalm™) P/N . AquaLink Z4 General Information • J-Box minimum 6 feet off the ground • J-Box minimum 8 feet from a blower • Signal distance – 500 feet (maximum) • Signal type – 900 MHz AQUALINK WIRELESS REMOTE CONNECTION Connect 4 conductor cable from the AquaLink Wireless Remote J-Box to the four pin terminal bar on the right side of the Z4 PCB. AquaLink Wireless Remote J-Box Cable 11 . Green Yellow Black Red INTAKE RETURN SOLAR FIL_PMP AUX 1 AUX 2 AUX 3 Note: Hot Keys Assign Hot Keys will only appear in the Install Settings Menu if the AquaLink Wireless Remote J-Box is installed and communicating. AQUALINK® WIRELESS REMOTE TIPS AND TRICKS AQUALINK WIRELESS REMOTE (AquaPalm™) P/N .AQPLM Install the AquaLink Wireless Remote per the installation manual. AquaLink Z4 TIPS AND TRICKS WHEN SETTING THE CHANNEL WRITE THE CHANNEL INSIDE THE J-BOX AND POWER CENTER ALWAYS TRY AND USE THE LAST NUMBER IN THE HOME ADDRESS COMMON KNOWN INTERFERANCE CHAINLINK FENCE HAM RADIO OLDER HOME WIRELESS PHONES STUCCO (CONTAINS CHICKEN WIRE) SPA AIR BLOWER (HAS WINDINGS) NEXT DOOR NEIGHBOR HAS PDA (CHANGE THE CHANNEL) NOTES: 12 . Grn Yel Blk Red INTAKE RETURN SOLAR FIL_PMP AUX 1 AUX 2 AUX 3 1 2 3 4 5 6 7 8 9 10 To Low Voltage Thermostat Heater 13 . INSTALLATION - LOW VOLTAGE HEATER LOW VOLTAGE (<50 volts) HEATER CONNECTION (GENERIC) Connect two conductor cable in series with the heater’s thermostat/safety circuit. Check the manufacture’s installation manual for the wire gauge and how to connect in series with the heater’s circuitry. LOW VOLTAGE HEATER WIRING (GENERIC) At the PCB of the Z4 connect the two wires to pins 1 and 2 of the 10 pin terminal bar. Run four (4) conductor cable.LXi With power off to the LXi heater and AquaLink® Z4. INSTALLATION - LOW VOLTAGE HEATER SMART HEATER CONNECTION . to the red four pin terminal bar at the top of the LXi Power Interface Board (PIB). Smart Heater Connection .LXi At the LXi PIB make connection as shown.LXi Connect the four conductor cable to the red terminal bar of the Power Interface Board (PIB) inside the LXi J10 J9 as follows: 4321 1 – Red wire Air/Coil H2O J12 2 – Black wire 3 – Yellow wire 4 – Green wire Run the cable to the AquaLink Z4. remove the front door of the heater. LXi Smart Heater Connection .LXi™ Connect 4 conductor (22 AWG min. SMART HEATER WIRING . J17 J16 J15 Power Interface Board (PIB) J6 J3 14 . minimum 22 AWG.) cable to the Red 4 pin terminal bar of the LXi PIB. The LXi and the AquaLink Z4 will begin to communicate when power is supplied to each.LXi Feed the four conductor cable through the low voltage compartment to the red terminal bar of the AquaLink Z4. NOTES: 15 . INSTALLATION - LOW VOLTAGE HEATER SMART HEATER WIRING . Green Yellow Black Red INTAKE RETURN SOLAR FIL_PMP AUX 1 AUX 2 AUX 3 Smart Heater Connection .LXi™ At the PCB of the Z4 connect the 4 conductor wire to the 4 pin terminal bar on the right. Make the connections as follows: LXi . turn power on. Turn on power to the heater and Z4 to start communication.Smart Heater 1 – Red wire 2 – Black wire Connection 3 – Yellow wire 4 – Green wire After completing the connections. T-STAT WIRING .LXi™ or LRZE With power off to the heater and Z4 feed two conductor wire to the heater’s PIB at the three pin terminal bar (J6). LXi T-Stat Heater Connection . INSTALLATION - LOW VOLTAGE HEATER T-STAT HEATER CONNECTION . 4321 Connect the two wires of the cable to Pool and Air/Coil H2O J12 Common. remove the front door.LXi or LRZE J10 J9 Locate the blue three (3) pin connector at J6. Do not connect to Spa.LXi or LRZE Connect two conductor wire to terminals POOL and COMMON of the three pin terminal bar (J6). T-Stat Heater Connection .LXi or LRZE With power off to the LXi or LRZE heater. J17 J16 J15 Power Interface Spa Board (PIB) Pool Common J6 J3 16 . Run two (2) conductor cable to the blue three pin terminal bar (J6) at the lower left of the Power Interface Board (PIB). LXi™ or LRZE At the PCB of the Z4 connect the two conductor cable to terminals 1 and 2 of the ten pin terminal bar. Access the Service Setup Menu by doing the following: With power on to the heater. When display changes to SELECT SERVICE SETUP release the buttons. but the heater off. To LXi or LRZE After completing the connections.LXI or LRZE Feed the two conductor cable through the low voltage compartment to the green ten (10) pin terminal bar of the AquaLink Z4 PCB. turn power on to J6 Terminal of PIB the AquaLink Z4 and heater. Grn Yel Blk Red INTAKE RETURN SOLAR FIL_PMP AUX 1 AUX 2 AUX 3 1 2 3 4 5 6 7 8 9 10 T-Stat Heater Connection . Follow the steps to configure the heater to recognize a two wire connection. T-STAT SETUP . INSTALLATION - LOW VOLTAGE HEATER T-STAT WIRING . 17 . Turn power on to the heater and Z4. HEATER IS OFF PRESS POOL OR SPA POOL SPA MENU Step 1 – Access Service Setup Menu Make certain power is on to the heater.LXi or LRZE Open the cover of the heater’s thermostat. Note: You must press the MENU button first because pressing either the POOL or SPA button will turn on the heater and you will not be able to access the Service Setup Menu. Hold all three buttons down together for 5 to 7 seconds. press and hold down first the MENU button then the POOL and SPA buttons. Connect wires to terminals 1 and 2. but the heater is off (not firing). LXi™ or LRZE SELECT SERVICE SETUP SELECT SERVICE SETUP REMOTE REMOTE TSTAT POOL SPA POOL SPA MENU MENU Step 2 – Select Remote Step 3 – Select REMOTE TSTAT In the Service Setup Menu use the Up or Scroll to REMOTE TSTAT then press MENU Down button to scroll to REMOTE. above the thermostat. 80 F) as apposed to the SPA thermostat which defaults to 39 C or 102 F. then to select. Next increase the thermostat to the maximum (40 C or 104 F) so the AquaLink Z4 will control the water temperature. If done correctly the green LED. * REMOTE TSTAT * HEATER IS OFF * ENABLED * PRESS POOL OR SPA POOL SPA POOL SPA MENU MENU Step 4 – Return to Main Screen Step 5 Press the POOL or SPA button to return to Enable the heater so it will fire when the the main screen. 18 . AquaLink Z4 calls for heat by pressing either the POOL or SPA buttons. but if you chose the POOL you will need to press the UP button many times to get to 40 C or 104 F (default 27 C. Note: You can either enable the POOL thermostat or SPA thermostat. will light and the display will read REMOTE TSTAT ENABLED. press the MENU button to select. INSTALLATION - LOW VOLTAGE HEATER T-STAT SETUP . Main Menu Flow Diagram - Pool/Spa Combination ** ** Note: There are 10 total Schedule (ON/OFF) times that can be entered into the Z4. NOTES: 19 . Install Setting Menu Flow Diagram - Pool/Spa Combination NOTES: 20 . . Main Menu Flow Diagram - n Pool Only System NOTES: 21 . Install Setting Menu Flow Diagram - Pool Only System 22 . 23 . DVS Z4 JUN 2015 .