Z4

INSTALLATION &
OPERATION
WORKBOOK
IMPORTANT SAFETY INSTRUCTIONS
The information contained in this technical guide is intended for Zodiac trained service personnel only.
Electrical installation and repairs should only be performed by a certified electrician or Zodiac trained
professional. and must comply with all national electric codes (NEC, Canadian, etc.). state and local law,
ordinances, codes and regulations.
If you have not received training, do not attempt any of the electrical repairs presented in this document.
Contact Zodiac Pool Stsyems, Inc. at 1-800-822-7933 for assistance.

Read and follow all instructions carefully.

When servicing equipment, basic safety precautions should always be followed including those listed
below.
Failure to heed the following warnings could result in property
! WARNING damage, permanent injury or death.

TO REDUCE THE RISK OF ELECTRICAL SHOCK:

Disconnect main power to pool equipment area prior to any service or repairs.
Keep all electrical equipment at least 10 feet (3m) from inside wall of pool or spa.
Connect equipment only to a receptacle (cord models) or circuit (hardwired) protected by a
ground fault circuit interrupter (GFCI).
Use only copper conductors and supply wires suitable for the specific device.
Replace damaged power cord(s) immediately and use only identical replacement parts.
Do not bury power cord(s). Position cord(s) to minimize abuse from lawn mowers, hedge
trimmers and other equipment.
Do not install or service equipment if precipitation is present or imminent.
TO REDUCE EQUIPMENT WATER PRESSURE HAZARD:
Always turn pump off to release pressure prior to removing or installing in-line equipment.
To avoid equipment damage, do not exceed water pressure (psi) specifications for
the device.
To reduce the risk of injury, do not permit children to operate, handle or play on equipment.

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Zodiac Pool Systems, Inc. Zodiac Academy
1-800-822-7933 zodiac.academy@zodiac.com
Regional Extension_________________ www.trainyu.com/zodiac
www.ZodiacPoolSystems.com

Instructor: __________________________________________________ ext. _______

Sales person: ________________________________________________ ext. _______
Service Manager: ____________________________________________ ext. _______

Notes:

4
 TABLE OFOFCONTENTS
TABLE CONTENTS

TABLE OF CONTENTS
FINISH GOODS PART NUMBERS and MODELS ..................................................6

USER INTERFACE ............................................................................................... 6

COMPONENTS .................................................................................................. 7
INSTALLATION
3 HP RELAY WIRING ...............................................................................8
TWO SPEED RELAY WIRING ................................................................... 9
SENSORS ...............................................................................................10
AQUALINK WIRELESS REMOTE (AQUAPALM) ....................................11
iAQUALINK...........................................................................................12
MULTIPLEX BOARD................................................................................12
JVAs ........................................................................................................13
HEATER CONNECTION (GENERIC) .........................................................14
MENU

HEATER CONNECTION (SMART - LXi) .................................................15 & 16

HEATER CONNECTION (T-STAT - LXi or LRZE) ......................................... 17 - 19
POOL AND SPA COMBINATION ..............................................................20 & 21
POOL ONLY ............................................................................................ 22 & 23

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 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, B=Feb, C=March, 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. If a power outage occurs the user inputs will not be lost even if
the battery is dead.
The 3 volt lithium battery keeps the clock running during a power outage. To access the battery open the power
center door, remove the two screws holding the User Interface in place, then remove the four screws.
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 COMPONENTS

POWER CENTER COMPONENTS

Transformer
Primary: 120 VAC, 60 Hz., 3 amp.
Secondary: Class 2, 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 1.5 horsepower motor when wired for 115 VAC.
Maximum 1500 Watts per contact

PRINTED CIRCUIT BOARD (PCB) COMPONENTS RS 485

connection
User Interface
3.15 amp fuse Connector.

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
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 INSTALLATION - RELAYS
WIRING

3 HP RELAY Relay coil resistance must be between 300

P/N - R0658100 and 400 Ohms. Measure resistance with coil
Coil (input): 24 VDC wire disconnected from the PCB.
Contacts: 3 horsepower when wired 240 VAC A shorted relay coil can damage the PCB.
1.5 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
 INSTALLATION - RELAYS
WIRING

2 SPEED RELAY
P/N - 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.

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 - Common

Connect from N.O. of relay to

Low Speed of Motor

Connect from N.C. of relay to

High Speed of Motor

Connect to Common of Motor

NOTES:

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 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.
Make certain the O ring is in place on the sensor housing.
Insert the sensor in the hole and clamp in place.
Solar Temperature Sensor
Mount the solar sensor (if applicable) next to the solar panels exposed to the same sun light.
Avoid splicing sensor wires.
Air Temperature Sensor
The Air Sensor comes factory installed to the bottom of the Power Center.
This sensor activates freeze protection when the air temperature reaches approximately 38 F.
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

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 INSTALLATION -
AQUALINK WIRELESS REMOTE

AQUALINK WIRELESS REMOTE (AquaPalm)

P/N - AQPLM
Install the AquaLink Wireless Remote per the installation manual.

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.

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 J-Box Cable

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 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:

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 INSTALLATION -
LOW VOLTAGE HEATER

LOW VOLTAGE (<50 volts) HEATER CONNECTION (GENERIC)

Connect two conductor cable in series with the heaters thermostat/safety circuit. Check the manufactures
installation manual for the wire gauge and how to connect in series with the heaters 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.

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

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 INSTALLATION -
LOW VOLTAGE HEATER

SMART HEATER CONNECTION - LXi

Connect 4 conductor (22 AWG min.) cable to the Red 4 pin terminal bar of the LXi PIB.

LXi Smart Heater Connection - LXi

With power off to the LXi heater and AquaLink Z4,
remove the front door of the heater. Run four (4)
conductor cable, minimum 22 AWG, to the red four
pin terminal bar at the top of the LXi Power Interface
Board (PIB).

SMART HEATER WIRING - LXi

At the LXi PIB make connection as shown.

Smart Heater Connection - 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.
J17

J16

J15
Power Interface
Board (PIB)
J6

J3

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 INSTALLATION -
LOW VOLTAGE HEATER

SMART HEATER WIRING - LXi

At the PCB of the Z4 connect the 4 conductor wire to the 4 pin terminal bar on the right. Turn
on power to the heater and Z4 to start communication.

Green
Yellow
Black
Red

INTAKE RETURN SOLAR FIL_PMP AUX 1 AUX 2 AUX 3

Smart Heater Connection - LXi

Feed the four conductor cable through the low voltage
compartment to the red terminal bar of the AquaLink Z4.
Make the connections as follows:
LXi - Smart Heater
1 Red wire
2 Black wire Connection
3 Yellow wire
4 Green wire
After completing the connections, turn power on. The LXi and
the AquaLink Z4 will begin to communicate when power is
supplied to each.

NOTES:

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 INSTALLATION -
LOW VOLTAGE HEATER

T-STAT HEATER CONNECTION - LXi or LRZE

With power off to the heater and Z4 feed two conductor wire to the heaters PIB at the three pin terminal bar (J6).

LXi T-Stat Heater Connection - LXi or LRZE

With power off to the LXi or LRZE heater, remove
the front door. Run two (2) conductor cable to the
blue three pin terminal bar (J6) at the lower left of
the Power Interface Board (PIB).

T-STAT WIRING - 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

J10 J9 Locate the blue three (3) pin connector at J6.
4321 Connect the two wires of the cable to Pool and
Air/Coil H2O

J12 Common. Do not connect to Spa.

J17

J16

J15
Power Interface
Spa Board (PIB)
Pool
Common
J6

J3

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 INSTALLATION -
LOW VOLTAGE HEATER

T-STAT WIRING - 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.
Turn power on to the heater and Z4.

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 - 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. Connect
wires to terminals 1 and 2. To LXi or LRZE
After completing the connections, turn power on to J6 Terminal of PIB
the AquaLink Z4 and heater.

T-STAT SETUP - LXi or LRZE

Open the cover of the heaters thermostat.
Follow the steps to configure the heater to recognize a two wire connection.

HEATER IS OFF
PRESS POOL OR SPA

POOL SPA

MENU

Step 1 Access Service Setup Menu

Make certain power is on to the heater, but the heater is off (not firing).
Access the Service Setup Menu by doing the following:
With power on to the heater, but the heater off, press and hold down first the MENU button
then the POOL and SPA buttons. Hold all three buttons down together for 5 to 7 seconds.
When display changes to SELECT SERVICE SETUP release the buttons.

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.
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 INSTALLATION -
LOW VOLTAGE HEATER

T-STAT SETUP - 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, then to select.
press the MENU button to select.

* 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
the main screen.
Enable the heater so it will fire when the
AquaLink Z4 calls for heat by pressing either
the POOL or SPA buttons. If done correctly
the green LED, above the thermostat, will
light and the display will read REMOTE
TSTAT ENABLED.
Next increase the thermostat to the
maximum (40 C or 104 F) so the AquaLink
Z4 will control the water temperature.

Note: You can either enable the POOL

thermostat or SPA thermostat, 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, 80 F) as apposed to the SPA thermostat
which defaults to 39 C or 102 F.
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 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

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DVS Z4 JUN 2015