Congratulations on purchasing the most advanced microprocessor-controlled, hot water recirculation pump controller made. This system is designed to run the recirculation pump only when you need it thus saving both water and energy.It is designed and built with pride in the USA to provide years of service and savings.
Unboxing Your Product
1 Smart Aquastat Control 32 with RJ-45 connector
1 Temperature Sensor with RJ-14 connector.
1 ¾” or 1” NPT Flow Sensor with JST connector
1 Wiring Harness with RJ-45, RJ-14 and JST connectors
Parts not included: The following items are needed for the installation, but are not included.
→ Electrical Tape → PTFE (Teflon) Tape → Wire fasteners for securing wiring to the wall
Before you begin
Perform the following system test.
Connect the wiring harness to the controller.
Connect the flow meter to the wiring harness.
Connect the temperature sensor to the wiring harness.
Plug the controller into a wall outlet and ensure that the LED on the controller flashes green 3 times.
Blow through the flow meter in the direction of the arrow and ensure the controller makes a slight audible click and the red LED turns on.
If this test fails, disconnect all connections and inspect the wires to ensure they are not broken or loose and that the pins in the temp sensor connector are not pushed to one side or the other.
Install the flow meter at the cold water input to the water heater ensuring the arrow on the flow meter points in the direction of flow.
NOTE: PTFE tape IS necessary when joining to a female NPT connector. PTFE tape is NOT necessary when connecting to a flexible hook-up line as they use a washer to create a seal. If installing in hard copper piping it is recommend to install the flow meter using a union fitting.
Attach the temperature sensor to smooth copper piping on the returning hot water line before the return line T’s into the cold water feed and upstream from the check valve. It is preferable to install the sensor upstream from the recirculation pump as the thermal mass of the pump can cause slightly longer run time. Ensure the entire length of the sensor is in contact with the pipe and secure it with electrical tape.
Do not attach it to a coupler, corrugated flex pipe or a hookup hose. Cover the temperature sensor with insulation. The temperature sensor lines can be extended with RJ-14 telephone line extensions if needed. Tested extensions can be purchased from the online store.
Connect the temperature sensor to the wiring harness using the RJ-14 connector, connect the flow meter to the wiring harness and plug the wiring harness into the controller.
Plug the controller into an outlet and plug the pump into the controller.
Turn a hot water faucet fully on for 1 second and the pump will turn on. If the hot water line is cold the pump will continue to run until hot water recirculates throughout the house and raises the temperature of the return sensor to 105°F (default).
If the pump fails to turn on or run for longer than 5 minutes and the piping feels hot, see Troubleshooting.
GREEN LED: will blink 3 times when first plugged in to indicate the unit is functioning correctly GREEN LED: solid on when a “Smart Timer”TM is active and pump is not running GREEN LED: will blink every 10 seconds when no other LED is lit (e.g. no timer active, pump not running) RED LED: fast blinking indicates that the temperature sensor is not connected properly RED LED: will blink every 5 seconds when Max Pump Run Time is exceeded. RED LED: solid on when the pump is running whether due to a timer or due to demand BLUE LED: solid on when connected via the smartphone app
Please read over the following detailed instructions. If you are not comfortable with any part of them please contact a licensed plumber to perform the installation.
Prior to installation, you must perform the system test at the beginning of the Quickstart Guide.
Note setting of the water heater thermostat and then set it to lowest temperature setting (do not turn off the pilot light).
Shut off the cold water supply to the water heater.
Open the closest hot water faucet to the water heater to depressurize the hot water line. When water quits flowing, turn off the faucet.
Disconnect the cold water supply line from water heater. Be careful not to bend and crease the supply line when manipulating it. Be prepared with some towels as some water will flow out of the hookup line. You don’t have to drain the tank. As long as all the faucets remain closed you should not get any back flow from the hot water line.
Connect the flow meter to the cold water input of the water heater using PTFE tape being sure that the arrow on the flow meter is pointing toward the water heater.
Connect the cold water supply line to the input side of the flow The supply line uses a washer to seal so you don’t need to use PTFE tape on this connection. Hand tighten and turn an additional ¼ to ½ turn. DO NOT OVER TIGHTEN!
Turn on the cold water supply to the water heater and inspect for leaks.
Turn the water heater thermostat back to its original temperature setting.
Locate the recirculation pump.
Attach the temperature sensor to smooth copper piping upstream from the pump with electrical tape ensuring the entire length of the sensor is in contact with the pipe. Do not attach it to corrugated copper pipe or a coupler. Cover the temperature sensor with insulation. You may install the sensor downstream from the pump however the pump absorbs heat requiring it to run longer before the temp sensor will see the increase in temperature.
NOTE: If installing with PEX
PEX is a good insulator and will cause a lag in the controller sensing the temperature change. You will need to plumb in a short section of copper pipe and attach the temperature sensors to the copper pipe instead of attaching the sensors directly onto the PEX.
NOTE: Temp sensor placement
Temperature sensor MUST be placed before the return line T’s back into the cold water supply line.
Connect the temperature sensor to the wiring harness using the RJ-14 connector ensuring it snaps together securely.
Connect the flow meter to the wiring harness via the JST connector ensuring it snaps together securely.
Secure the wires to the wall away from the water heater.
Plug the wiring harness into the Smart Aquastat Control 32 via the RJ-45 connector ensuring it snaps in securely.
Plug the recirculation pump into the Smart Aquastat Control 32 and plug the Smart Aquastat Control 32 into an electrical outlet.
The green LED on the side of the controller will blink 3 times if everything is OK. If the red LED flashes quickly see Troubleshooting Symptom 1.
Turn a hot water faucet fully on for 1 second. If the hot water line is cold the recirculation pump will turn on. The red LED turns on while the pump is running.
If the hot water line is cold the pump will continue to run until the temperature reaches 105°F (default off value)
The temperature of the sensor and the status of the pump can be monitored via the smart phone app by selecting “Live Data”TM from the menu.