Calorex Pro-Pac 8-22kw User Manual
Contents
1. COMPRESSOR O LOAD ALARM SOFT START THERMAL OVERLOAD mn amp FAULT LIGHT IF FITTED 1 SOLENOID VALVE PPT22ALX ONLY POOL STAT SENSOR DEFROST SENSOR WATER TEMP COMPRESSOR O LOAD ALARM E LL 97 98 LP SWITCH FLOW SWITCH BREAKS ON PRESSURE FALLING DIGITAL INPUTS HP SWITCH BREAKS ON NIC PRESSURE REMOTE ON OFF RISING INTERLOCK SOLENOID VALVE OUTA CONTROL FUSE 21 3A SUPPLY Q O f 24 N FUSE RATINGS MODEL PPT16ALX PPT22ALX VOLT FREE POOL PUMP RUN MAX 3Amps OVERLOAD SETTING MODEL NEUTRAL PPT16ALX PPT22ALX Page 18 SD638153 ISSUE 10 Calorex Heat Pumps Ltd The Causeway Maldon Essex 9 4XD UK Installation Manual PPT8 12 16 22LX LY SLIMLINE CONTACTOR N O si SOFT START THERMAL OVERLOAD amp FAULT LIGHT IF FITTED 2 SOLENOID VALVE B PPT22BLX ONLY POOL STAT SENSOR DEFROST k 40 gt 12 K SENSOR WATER TEMP FLOW SWITCH LP SWITCH CLOSE FLOW BREAKS ON PRESSURE FALLING DIGITAL INPUTS HP SWITCH BREAKS ON PRESSURE RISING REMOTE ON OFF INTERLOCK SOLENOID REVERSIN2. o o POINT ELEC BOX EARTH STUD MAKE MAINS IN EARTH CONNECTION HERE THREE PHASE 400V 3N 50Hz L1L2L3 VOLT FREE POOL PUMP RUN TERMINALS 6115 10 ES REMOTE ON OFF INTERLOCKS 95 CABLE ENTRY POINT 5 6 7 8 910111213141318171 ig olololololololololelolololojo 14 EARTH STUD MAKE MAINS IN EARTH CONNECTION HERE SD638153 ISSUE 10 Calorex Heat Pumps Ltd The Causeway Maldon Essex 9 4XD UK Installation Manual PPT8 12 16 22LX LY SLIMLINE 4 3 Pool Pump For installations where the filter pump which also provides water to your Synchronisation heat pump is controlled by a time clock supplied by the installer your Calorex heat pump can overridde pump off periods set on the time clock so that the filter pump will run if your swimming pool requires heating By doing so your filter pump will only run when a Ablock period of pump running has been set on the time clock for filtration purposes b The pool requires heating This feature operates by overriding the filter pump time clock for
3. POOL WATER WATER ps CONDENSATE DRAIN REMOVE BUNGS BEFORE INSTALLING HEAT PUMP PPT8 12 FLOW RATE 4500 L hour PPT16 FLOW RATE 7500 L hour PPT22 FLOW RATE 9960 L hour Page 11 SD638153 ISSUE 10 Calorex Heat Pumps Ltd The Causeway Maldon Essex 9 4XD UK Installation Manual PPT8 12 16 22LX LY SLIMLINE 4 0 Electrolytic Corrosion Electrolytic corrosion will occur when dissimilar metals that are in contact in Swimming Pools with each other create a potential difference between themselves Sometimes separated by a conductive substance known as an electrolyte the dissimilar metals will create a small voltage potential difference that allows the ions of one material to pass to the other Just like a battery ions will pass from the most positive material to the more negative material Anything more than 0 3 volts can cause the most positive material to degrade Aswimming pool with its associated equipment can create this effect The pool water being an ideal electrolyte and components of the filtration circuit heating system steps lights etc providing the dissimilar metals needed to complete the circuit Whilst these small voltages are rarely a safety threat they can create premature failure through corrosion Not dissimilar to corrosion through oxidation electrolytic corrosion can cause complete failure of a metallic material
4. 3 1 d Suitable breakable couplings should be installed local to the heat pump e If the heat pump is installed at a lower level than the pool then isolation valves should be fitted f Adrain valve or plug should be fitted to the lower pipe to facilitate drain down in the winter period g Connections on all models are by 1 72 or 50mm Female fittings The water in water out pipes need to be glued into these connections using a suitabe adhesive h The condensate drain at the base of the unit collects condensation from the evaporator fins This should run away to waste 4 domestic waste piping It is therefore necessary to ensure that the Calorex Heat Pump is placed on a level plinth so that the condensate water can run away with adequate fall to waste i e 72 per foot minimum and must incorporate a u trap as to not overflow the edges of the drip tray inside the heat pump See below THIS TYPE OF INSTALLATION INCORRECT DRAINAGE SHOULD BE AVOIDED CORRECT DRAINAGE FOR CONDENSATE FOR CONDENSATE a ADEQUATE FALL 8 SD638153 ISSUE 10 Calorex Heat Pumps Ltd The Causeway Maldon Essex CM9 4XD UK Installation Manual PPT8 12 16 22LX LY SLIMLINE i When the pipework installation is complete the pool pump should be switched on and the system tested for leaks Also check the filter gauge to see that there is not an excessive increase in b
5. Calorex swimming where it is compressed and pool heat pumps high volumes of outside air are drawn into the upgraded to a much higher unit by the fan expelled through the evaporator fins The temperature The hot vapour evaporator has liquid refrigerant passing through it which is at a now enters considerably lower temperature than the ambient air Therefore the air gives up its heat to the refrigerant which then vaporises This preheated vapour now travels to THE HEAT PUMP CYCLE COMPRESSOR COOL GAS POOL WATER OUT HEAT EXCHANGER POOL WATER IN gt CONDENSED COOL LIQUID REFRIGERANT REFRIGERANT EXPANSION VALVE LOW PRESSURE SIDE HIGH PRESSURE SIDE 4 THE EXPANSION DEVICE and from 3 THE CONDENSER where it is surrounded there now at normal pressure it is by the pool water The heat is given up to the returned to the evaporator and the cycle cooler pool water and the now cooler refrigerant starts again returns to its former liquid state but still under high pressure from the compressor This pressure is released by passing liquid through Coefficient of Performance The efficiency of a Heat Pump is usually called its Coefficient of Performance C O P which is simply a ratio of heat output to energy input both being expressed in KW Thus a Heat Pump absorbing 1 kW of electricity collecting 4 kW of energy from the air and delivering 5 kW of heat to the pool water is said to have a C O P of 5 1 This
6. ratio will vary according to the temperature of the water and the ambient air Page 5 SD638153 ISSUE 10 Calorex Heat Pumps Ltd The Causeway Maldon Essex CM9 4XD UK Installation Manual PPT8 12 16 22LX LY SLIMLINE 2 0 Installation a Ensure heat pump on site is as ordered i e model electrical supply and factory fitted options b Inspect unit for damage in particular inspect the evaporator finned side to ensure that it is undamaged Minor indentations in the fins do not affect performance If severely damaged endorse delivery note in presence of the driver and send a recorded delivery letter to transport company giving details Protect unit if installation is delayed 2 1 Accessories The heat pump is supplied with accessories which aid installation On delivery the accessories are in a plastic bag in the heat pump electric box See section 4 2 for lid removal These accessories are as follows 4 x rubber feet Fit these under the metal feet of the heat pump to help reduce the effects of vibration 2 x 50mm female connectors On delivery the heat pump has 1 1 2 sockets attached to the water connections for fitting 1 1 2 plastic pipes If 50mm pipework is preferred undo the threaded couplings on the water in out connection points and carefully remove the 1 1 2 sockets Then fit the 50mm sockets in their place and refit the threaded couplings The heat pump can then be fitted with 50mm plastic pipe 2 x Condens
7. start stop manual defrost Decrease Set Point DEFROST LAMP Access Set Point WATER HEATING LAMP FAN LAMP Set Lamp ALARM LAMP FAULT AUX LAMP POOL PUMP NOT USED CHILLING Page 16 SD638153 ISSUE 10 Calorex Heat Pumps Ltd The Causeway Maldon Essex 9 4XD UK Installation Manual PPT8 12 16 22LX LY SLIMLINE 6 0 Circuit Diagrams RUN CAP CONTACTOR N O 5 6 NES 5 COMPRESSOR RELAY HARD START CAP IF FITTED SOFT START THERMAL OVERLOAD n lt gt amp FAULT LIGHT IF FITTED SENSOR DEFROST K K SENSOR WATER TEMP LP SWITCH FLOW SWITCH BREAKS ON PRESSURE FALLING DIGITAL INPUTS HP SWITCH BREAKS ON PRESSURE RISING REMOTE ON OFF INTERLOCK SOLENOID VALVE CONTROL FUSE 3A Q O FUSE RATINGS SUPPLY i 23 24 i N i MODEL PPT8ALX MAX 3Amps VOLT FREE POOL PUMP RUN PPT12ALX NEUTRAL Page 17 SD638153 ISSUE 10 Calorex Heat Pumps Ltd The Causeway Maldon Essex 9 4XD UK Installation Manual PPT8 12 16 22LX LY SLIMLINE PPT16 22 ALX SINGLE PHASE 230V 1N 50Hz RELAY HARD START CAP CONTACTOR O LOAD 1 OFF PPT16 0 2 22 a 00 2 SOFT STAR 9 5
8. that the test is carried out For machines affected see datasheet section 9 0 Asample log sheet can be seen below General Information Plant Name CSS re Nbr Location of Plant Plant Operator Operator Contact Refrigerant Type Refrigerant Quantity installed kg Plant manufacturer Calorex Heat Pumps Limited Year of installation Refrigerant Additions Engineer Date Engineer Amount Added k Reason for addition Company Name Amount Addedkg Femontradi on Refrigerant Removals R f What d ith d Date Ari dant REMC KG MRNA n removal What done with recovere Leak Tests Date Test Result Follow up action required Follow up Actions Engineer Date Enner Related to test on Actions taken Company MENS NE Testing of Automatic Leak Detection Ie if fitted Name and address of company operating plant Contact details for operator s nominated person responsible for F Gas compliance 3 Company and technician carrying out work with details to provide evidence of compliance Page 33 SD638153 ISSUE 10 Calorex Heat Pumps Ltd The Causeway Maldon Essex 9 4XD UK
9. 20 WATER 24 2 5 2 8 4 3 MIN SUPPLY CAPACITY Max F L A 1 ph N MIN SUPPLY CAPACITY Max F L A 3 ph N i 64 8 0 RECOMMENDED SUPPLY FUSE 1 ph N RECOMMENDED SUPPLY FUSE 3 ph N WATER FLOWS ETC POOL WATER FLOW RATE L min 75 75 125 POOL WATER PRESSURE DROP Rated Flow m hd 0 1 0 1 0 1 0 6 MAX WORKING PRESSURE POOL WATER bar 2 5 2 5 3 5 3 5 POOL WATER CONNECTIONS inches 1 1 2 or 50mm Female CONDENSATE DRAIN CONNECTIONS inches 3 4 DOMESTIC WASTE COMPRESSOR NOMINAL POWER CONSUMED 1 6 3 2 L R A 1 ph N 62 R L A 1 ph N 25 SOFT START AMPS 1 ph N 28 37 L R A 3 ph N 32 48 R L A 3 ph N 4 10 SOFT START AMPS 3 ph N 14 25 MAIN FAN AIR FLOW Anemometer air on grille Dry evaporator F L A 1 ph N GENERAL DATA HERMETIC SYSTEM GAS CHARGE R407c SOUND PRESSURE LEVEL 3m AIR ON SOUND PRESSURE LEVEL 3m AIR OFF SOUND PRESSURE LEVEL 3m SIDE SOUND POWER PHYSICAL DIMENSIONS WIDTH Unpacked mm 1264 DEPTH Unpacked mm 594 HEIGHT Unpacked mm 725 WEIGHT Unpacked ALY kg N A WEIGHT Unpacked BLY kg WEIGHT Packed ALY kg N A WEIGHT Packed BLY kg N A FOR ACCURATE APPLICATION SIZING CONSULT CALOREX HEAT PUMPS LTD Page 24 SD638153 ISSUE 10 Calorex Heat Pumps Ltd The Causeway Maldon Essex 9 4XD UK Installation Manual PPT8 12 16 22LX LY SLIMLINE WATER IN OUT 172 or 50
10. 53 ISSUE 10 gt ANWA AVM 338H L Na ANTWA NON mU 3 18VMxV3ua 3AT1VA NOLLV IOSI P A3 ALSVM OL NOILOANNOO H31VM 31VSN3QONO2 Q3 LLIJ YASILINVS 4l ONIHSN14 LYOd 191110 SNISIS3 LNIM a3so19 LV3H Sao ATIVINHON LHOISH WAWININ JAYA SSVdAd O31VHOdHOONI 38 OL LLNV ALSVM OL dWNd SNISIS3 LNIA X3HO lVO 315 OL sl 39IA3 SNISOG 1VOIW3HO al H3JSILINVS W3lvaH xnv tion 3 1 Recommended Plumbing Schematic l lt N S AX Installa UK Essex CM9 4XD Page 10 Maldon Calorex Heat Pumps Ltd The Causeway Installation Manual PPT8 12 16 22LX LY SLIMLINE 3 2 Determinin The heat pump is fitted with a water flow switch which inhibits the operation Water Flow of the heat pump when the water flow is less than the figure shown in the table below MODEL Flow rates for water pressure switch Machine starts working Machine stops working when flow rate rises if flow rate drops below above L hour L hour Adjust the flow rate until the flow rate is adequate The display on the digital thermostat shows noF until adequate flow is reached HP S _ GO DO X31SXx DIGITAL THERMOSTAT X
11. D638153 ISSUE 10 Calorex Heat Pumps Ltd The Causeway Maldon Essex 9 4XD UK Installation Manual PPT8 12 16 22LX LY SLIMLINE 9 0 Datasheets HEAT PUMPS FOR OUTDOOR POOLS SUMMER SEASON ALX BLX MODEL Units PPT8 PPT12 HEAT TO POOL WATER AMBIENT 10 C WATER 24 C 7 2 AMBIENT 20 C WATER 24 C 9 2 ELECTRICITY ELECTRICAL SUPPLY 1 PHASE 230V 1N 50Hz ELECTRICAL SUPPLY 3 PHASE 400 3 50 2 TOTAL POWER CONSUMED AMBIENT 10 C WATER 24 C 1 8 23 2 6 4 1 AMBIENT 20 WATER 24 2 0 2 5 2 8 4 3 MIN SUPPLY CAPACITY F L A 1 ph N 17 0 19 8 MIN SUPPLY CAPACITY Max F L A 3 ph N 6 0 64 8 0 RECOMMENDED SUPPLY FUSE 1 ph N 25 0 30 0 RECOMMENDED SUPPLY FUSE 3 ph N 10 0 15 0 WATER FLOWS ETC POOL WATER FLOW RATE L min 75 75 125 POOL WATER PRESSURE DROP Rated Flow m hd 0 1 0 1 0 1 0 6 MAX WORKING PRESSURE POOL WATER bar 2 5 2 5 3 5 3 5 POOL WATER CONNECTIONS inches 1 1 2 or 50mm Female CONDENSATE DRAIN CONNECTIONS inches 3 4 DOMESTIC WASTE COMPRESSOR NOMINAL POWER CONSUMED 1 6 i 3 8 L R A 1 ph N 62 R L A 1 ph N 25 SOFT START AMPS 1 ph N 28 37 L R A 3 ph N 32 48 R L A 3 ph N 4 3 10 SOFT START AMPS 3 ph N 14 25 MAIN FAN AIR FLOW Anemometer air on grille Dry evaporator F L A 1 ph N GENERAL DATA HERMETIC SYSTEM GAS CHARGE R407c SOUND PRESSURE LEVEL 3m AIR ON SOUND PRESSURE LEVEL 3m A
12. G VALVE o VOLT FREE POOL PUMP RUN MAX 3A 1 2 HP MCB SETTING MODEL CONTROL CIRCUIT ROTATION dier NEUTRAL BREAKER RELAY PPT16BLX PPT22BLX Page 19 SD638153 ISSUE 10 Calorex Heat Pumps Ltd The Causeway Maldon Essex 9 4XD UK Installation Manual PPT8 12 16 22LX LY SLIMLINE PPT22 ALY SINGLE PHASE 230V 1N 50Hz SOFT CONTACTOR O LOAD RELAY HARD A START CAPS 5 No RUN CAP COMPRESSOR O LOAD ALARM SOFT START THERMAL R OVERLOAD 8 FAULT i LIGHT IF FITTED SENSOR DEFROST K sensor WATER TEMP COMPRESSOR O LOAD ALARM 97 98 FLOW SWITCH LP SWITCH BREAKS ON PRESSURE FALLING HP SWITCH BREAKS ON PRESSURE REMOTE ON OFF RISING INTERLOCK DIGITARINEUTS REVERSING VALVE CONTROL FUSE 3A FUSE RATINGS VOLT FREE POOL PUMP RUN MAX 3A 1 2 HP MODEL PPT22ALY 3A OVERLOAD SETTING NEUTRAL MODEL PPT22ALY Page 20 SD638153 ISSUE 10 Calorex Heat Pumps Ltd The Causeway Maldon Essex 9 4XD UK Installation Manual PPT8 12 16 22LX LY SLIMLINE 7 0 Regular planned Op
13. IR OFF SOUND PRESSURE LEVEL 3m SIDE SOUND POWER PHYSICAL DIMENSIONS WIDTH Unpacked mm DEPTH Unpacked mm 594 HEIGHT Unpacked mm WEIGHT Unpacked ALX kg 91 WEIGHT Unpacked BLX kg WEIGHT Packed ALX kg 110 WEIGHT Packed BLX kg 110 FOR ACCURATE APPLICATION SIZING CONSULT CALOREX HEAT PUMPS LTD NOTES 1 Weight and dimensions nett DIMENSIONS INCLUDE WATER IN OUT STUBS AND MAINS IN CABLE GLAND 2 Performance design limitations Ambient 5 C min 40 C max Water 10 C min 40 C max 3 Pool water to have correct balance pH 7 2 7 8 Free Chlorine 1 0 2 0ppm domestic 3 0 6 0 commercial 4 Allow 500mm clearance to service panels 5 Calorex reserve the right to change or modify models without prior notice 6 R407c Global warming potential GWP 1700 1mm WG 9 8 1mhd 1 4 psi 1 0 22gall min Page 23 SD638153 ISSUE 10 Calorex Heat Pumps Ltd The Causeway Maldon Essex 9 4XD UK Installation Manual PPT8 12 16 22LX LY SLIMLINE 9 0 Datasheets HEAT PUMPS FOR OUTDOOR POOLS REVERSE CYCLE DEFROST ALY BLY MODEL HEAT TO POOL WATER AMBIENT 0 C WATER 24 C AMBIENT 10 C WATER 24 C AMBIENT 20 C WATER 24 C ELECTRICITY ELECTRICAL SUPPLY 1 PHASE 230V 1N 50Hz ELECTRICAL SUPPLY 3 PHASE 400 3 50 2 TOTAL POWER CONSUMED AMBIENT 0 C WATER 24 C N A N A 3 8 AMBIENT 10 C WATER 24 C j 23 2 6 4 1 AMBIENT
14. Installation Manual PPT8 12 16 22LX LY SLIMLINE OWNER INSTALLATION MANUAL FOR PPT8 12 16 22LX LY SLIMLINE SD638153 Iss 10 08 11 12 Health and Safety Warning As the heat pump includes electrical and rotational components it is required that only trained and competent persons should remove panels giving internal access to the unit SD638153 ISSUE 10 Calorex Heat Pumps Ltd The Causeway Maldon Essex CM9 4XD UK Installation Manual PPT8 12 16 22LX LY SLIMLINE Thank you for choosing Calorex Your Calorex heat pump has been specially designed for pool heating using high quality components that are carefully chosen to provide maximum efficiency and reliability Please read this manual carefully as it provides useful operation and maintenance information that will maximise the benefits your Calorex heat pump can offer M E p ACCESSORIES 4 x ANTIVIBRATION PADS 2 x 50mm FEMALE PIPE ADAPTORS 1 x CONDENSATE DRAIN SOCKET 3 4 1 X CONDENSATE DRAIN SOCKET 20mm IN HEAT PUMP ELECTRIC BOX 50638153 ISSUE 10 Calorex Heat Pumps Ltd The Causeway Maldon Essex CM9 4XD UK Installation Manual PPT8 12 16 22LX LY SLIMLINE D QUICK START GUIDE
15. TAT WATER OUT Page 28 50638153 ISSUE 10 Calorex Heat Pumps Ltd The Causeway Maldon Essex CM9 4XD UK Installation Manual PPT8 12 16 22LX LY SLIMLINE 11 0 Winterisation Procedure WARNING Isolate machine before removing covers The heat pump embodies electrical and rotational equipment it is recommended for your own safety that a competent person carries out the following procedure ALL MODELS Objective To provide frost protection To eliminate corrosion problems To inhibit electrical components 1 Switch off electric supply to heat pump 2 Remove external fuses and keep in safe place away from heat pump to prevent accidental operation of heat pump 3 Ensure water circulation pump is switched off 4 Drain water from heat pump by b disconnecting pipework to and from heat pump a drain valve if fitted 5 Flush through water circuit in heat pump by using CLEAN TAP WATER NOT POOL WATER via hose into outlet connection run the hose for 10 minutes minimum use spray nozzle if available 6 Allow to drain when drained fit plastic bags secured by elastic bands over water connections 7 Uncover electrical enclosure see section 4 2 and liberally spray interior of unit with moisture repellant aerosol WD40 or similar reseal enclosure 8 If heat pump locat
16. ack pressure If everything is then working normally the water circulating system is ready for use j Water circuit to and from the unit is to be capable of maintaining within specified limits the rate of flow required by the heat pump See section 9 k All pipework must be adequately supported with allowance expansion contraction especially with plastic pipework It is recommended that when installing water systems the last connections to be made in the system should be breakable connections to avoid any stresses on the unit connections IMPORTANT 1 All Pool Purifying Devices and Chemical Injection Systems to be fitted down stream of the heat pump see section 3 1 unless installation is as per filter dosing This includes the practice of dosing chemicals direct into skimmer basket which results in concentrated corrosive liquids passing over vulnerable metal components 2 Water quality must be maintained as follows I Acidity pH pH 72 78 Total Alkalinity as CaCOs Total Hardness as Total Dissolved Solids Maximum Salt Content Free Chlorine Range Free Chlorine Range Superchlorination Bromine Baquacil Ozone Maximum Copper Content Aquamatic lonic Purifier 3 Maximum pressure of water in heat pump circuit should not exceed 2 5bar for PPT8 12 35 psi and 3 5bar for PPT16 22 50 psi Page 9 SD638153 ISSUE 10 Calorex Heat Pumps Ltd The Causeway Maldon Essex 9 4XD UK SD6381
17. ate drain piece Condensate drain pieces are supplied suitable for 3 4 or 20mm pipe Use whichever piece fits the drain pipe required Glue the relevant piece to the driptray outlet and then fit then condensate drain piping 2 2 Siting a Provide a firm level base capable of supporting operational weight of unit spread load if mounted on timber floor b Ensure water cannot collect under unit it is recommend that units are installed on plinths 100mm above finished floor level This also aids condensate drainage C Allow adequate clearance to service panels on unit recommend 500mm minimum d All Calorex heat pumps are by design as quiet as is practical however due consideration should be given to siting the heat pump in order to minimise the noise coming from the machine for example by positioning the machine so that the inlet outlets are parallel to occupied premises Ensure loose debris such as leaves grass cuttings etc will not block air inlet grilles f Consider protection from extreme weather conditions if installed externally i e lean to cover or building Page 6 SD638153 ISSUE 10 Calorex Heat Pumps Ltd The Causeway Maldon Essex 9 4XD UK Installation Manual PPT8 12 16 22LX LY SLIMLINE 2 3 Air flow Due consideration must be given to air flow i e do not obstruct inlet or outlet and ensure discharge to air cannot recirculate to inlet See below POSSIBLE POSITIONS OF A CALOREX HEAT PUMP uitabl
18. ating in ambient temperatures above 5 C Reverse cycle defrost models designated Y operate in ambient temperatures down to 15 C The water heat exchanger is a full flow type manufactured from titanium tube which is a highly corrosion resistant material The heat pumps are suitable for use in fresh water and salt water pools PPT8 12 heat pumps are fitted with rotary compressors and PPT16 22 heat pumps are fitted with scroll compressors Both types of compressor are known for quiet running A6 minute compressor start delay timer is incorporated for compressor protection With these features the heat pump is designed to have a long trouble free life All units have integral safety devices to protect the heat pump from internal and external faults Indicator lamps indicate operating mode An adjustable digital thermostat controls water temperature Calorex Heat Pumps Limited is an 1509001 2000 certified company All Calorex heat pumps are CE approved Page 4 SD638153 ISSUE 10 Calorex Heat Pumps Ltd The Causeway Maldon Essex 9 4XD UK Installation Manual PPT8 12 16 22LX LY SLIMLINE 1 1 Function The Calorex Swimming pool heat pump provides thermodynamic heating by means of a vapour compression cycle similar to that employed in a conventional refrigerator in addition to acting as an active solar collector 1 THE EVAPORATOR collects the heat from the outside 2 THE COMPRESSOR ambient air pre heated by the sun In the
19. e opening _Suitable opening lt NEY gt 50 PLANT SWIMMING POOL SPA Ln TABLE 1 Required Free Areas to provide air flow to and Minimum Free Area m from heat pumps when installed in an Inlet Discharge enclosed area or where required to pass air 0 157 0 168 through a wall etc 0 264 0 168 0 322 0 173 Free areas is the available area through which 0 322 0 173 air can pass through a grille or louvres IMPORTANT If multiple units are installed in an enclosed area then the inlet free areas required for each unit can be added together to form one inlet aperture BUT discharge from each unit must be kept separate and must not be incorporated into one common duct system Page 7 SD638153 ISSUE 10 Calorex Heat Pumps Ltd The Causeway Maldon Essex 9 4XD UK Installation Manual PPT8 12 16 22LX LY SLIMLINE 3 0 Plumbing a Calorex Heat Pumps have water inlet outlet connections as follows All models have fittings which enable the heat pump to be connected to either 1 72 or 50mm pipe work b The heat pump is supplied with bungs fitted in the water connection fittings These need to be removed before the heat pump is installed See section 3 2 C The Calorex Heat Pump must be connected after the filter in the return pipe to the pool If an existing heater is being retained then the Calorex Heat Pump should be connected between the filter and the other heater See section
20. ed outside protect from weather by covering with VENTILATED cover Do not use plastic sheet as condensation could occur within unit IMPORTANT If this procedure is not adopted and frost or corrosion damage results then the warranty will become invalid Page 29 SD638153 ISSUE 10 Calorex Heat Pumps Ltd The Causeway Maldon Essex 9 4XD UK Installation Manual PPT8 12 16 22LX LY SLIMLINE 11 1 Start up Procedure 1 Replace covers if not fitted After Winterisation 2 Remove front grille Using a soft brush clean finned surfaces of heat pump Replace panel 3 Remove plastic covers on water connections and reconnect water piping or close drain valve 4 Start up water circulating pump and leave running for at least 1 4 hour to establish flow and enable an air in piping to escape 5 Replace fuses to heat pump circuit 6 Switch on heat pump 7 Check control thermostat is set to required pool temperature 8 Check pool water daily to ensure it is at correct pH and has correct chemical balance See Section 3 Plumbing Page 30 SD638153 ISSUE 10 Calorex Heat Pumps Ltd The Causeway Maldon Essex 9 4XD UK Installation Manual PPT8 12 16 22LX LY SLIMLINE 12 0 Warrant The following exclusions apply to the Warranty given by Calorex Heat Pumps Conditions Ltd No claims will be accepted if The heat pump is incorrectly sized for the application The heat pump is installed in any way that is no
21. erations to be carried out during a regular planned maintenance visit are maintenance as follows 1 Clean the evaporator This action may be required more frequently than regular servicing 2 Check operation of fan and compressor 3 Check capacitor tolerances where fitted 4 Check condition of all heat exchangers evaporators 6 Check operation of control valves 7 Check for water leaks 5 Check refrigeration system parameters 8 Check driptray and internal drain lines for blockages and flush through if necessary 9 Check operation of controls and calibrate if necessary 10 Check operation of interlocks in use 11 Final check of overall operation of unit 12 Indicate on Service report any faults found or causes for concern 13 Recommended servicing frequency one visit per year Page 21 SD638153 ISSUE 10 Calorex Heat Pumps Ltd The Causeway Maldon Essex 9 4XD UK Installation Manual PPT8 12 16 22LX LY SLIMLINE 8 0 Heat Pump WARNING Isolate heat pump electrically before entering heat pump or Malfunction removing panels The user check list should be carried out before initiating a service call Do not attempt to interfere with any internal control settings as these have been factory calibrated and sealed Any sign of abnormal operation such as water dripping should be reported immediately to the installer If in doubt or if advice is required contact Calorex Service Depar
22. i IT H R C MCB Type C 10 OO PPT8 20A PPT12 25A PPT16 30A PPT22 42A f 8 10A PPT12 104 16 15 PPT22 204 Calorex Pumps Ltd The Causeway Maldon Essex 9 4XD UK Installation Manual PPT8 12 16 22LX LY SLIMLINE Contents QUICK START GUIDE 1 0 Introduction 1 1 Function 2 0 Installation 2 1 Accessories 2 2 Siting 2 3 Air flow 3 0 Plumbing 3 1 Recommended Plumbing Schematic 3 2 Determining Water Flow 4 0 Electrolytic Corrosion in Swimming Pools 4 1 Electrical Machine Wiring and Supply 4 2 Location of Mains Input and External Interlock Terminals 4 3 Pool Pump Synchronisation 5 0 Digital Thermostat 6 0 Circuit Diagrams 7 0 Regular planned maintenance 8 0 Heat Pump Malfunction 8 1 User Check List 9 0 Datasheets 10 0 Installation Drawings 11 0 Winterisation Procedure 11 1 Start up Procedure After Winterisation 12 0 Warranty Conditions 13 0 Contacting Calorex 14 0 Machine Record Log Page 3 SD638153 ISSUE 10 Calorex Heat Pumps Ltd The Causeway Maldon Essex 9 4XD UK Installation Manual PPT8 12 16 22LX LY SLIMLINE 1 0 Introduction The Calorex Propac range of air to water heat pumps is designed for swimming pool heating and consists of 4 models Heat pumps in this manual are designed to heat pool water and spas within the range of 10 C to 40 C Standard units designated X are suitable for outdoor pools Oper
23. in a very short period of time In order to prevent this type of corrosion all metallic components in contact with swimming pool water should be bonded together using 10mm bonding cable This includes non electrical items such as metal filters pump strainer boxes heat exchangers steps and handrails It is highly recommended that bonding be retrofitted to existing pools which may not be protected by this system Page 12 SD638153 ISSUE 10 Calorex Heat Pumps Ltd The Causeway Maldon Essex 9 4XD UK Installation Manual PPT8 12 16 22LX LY SLIMLINE 4 1 Electrical Machine All electrical work to be carried out in accordance with I E E standards latest Wiring and Supply issue or local codes of practice as applicable The machine should be installed in line with EMC2004 108 EC Protected supply to incorporate fuses or motor type circuit breakers Type C to specified rating see Data Sheet H R C fuses are recommended An isolator which disconnects all poles must be fitted within 2m and in sight of machine T All units must be correctly earthed grounded An earth leakage trip of the Current operating type 30mA is recommended to be fitted to all pool electrics INCONSISTENT ELECTRICAL SUPPLY The following limits of operation must not be exceeded if Calorex machines are to be guaranteed either in performance or warranty terms Minimum Maximum Voltage single phase 207V 253V Voltage three phase 360V 440V Frequenc
24. mm FEMALE CONDENSATE 34 DOMESTIC WASTE PPT8 MAINS IN THERMOSTAT CONDENSATE AIR OFF WATER OUT WATER IN Page 25 SD638153 ISSUE 10 Calorex Heat Pumps Ltd The Causeway Maldon Essex 9 4XD UK Installation Manual PPT8 12 16 22LX LY SLIMLINE CONDENSATE 77 DOMESTIC WASTE WATER IN OUT 172 or 50mm Female PPT12 o MAINS IN 9 CONDENSATE Al s AIR OFF 854 WATER IN Page 26 SD638153 ISSUE 10 Calorex Heat Pumps Ltd The Causeway Maldon Essex 9 4XD UK Installation Manual PPT8 12 16 22LX LY SLIMLINE PPT16 1 72 or 50mm FEMALE CONDENSATE 34 DOMESTIC WASTE AIR OFF Page 27 SD638153 ISSUE 10 Calorex Heat Pumps Ltd The Causeway Maldon Essex 9 4XD UK Installation Manual PPT8 12 16 22LX LY SLIMLINE WATER IN OUT 172 or 50mm FEMALE CONDENSATE 74 DOMESTIC WASTE PPT22 THERMOS
25. t in accordance with the current procedures as defined by Calorex Heat Pumps Ltd The heat pump has been worked upon or is adjusted by anyone other than a person authorised to do so by Calorex Heat Pumps Ltd The air flow to and from the machine is outside the specified limits The water flow through the machine is outside the specified limits The water pH level and or chemical balance is outside the following limits 1000 Max 3 6 Commercial 2 5 2 Max 7 The heat pump has suffered frost damage 8 The electrical supply is insufficient or in any way incorrect Page 31 SD638153 ISSUE 10 Calorex Heat Pumps Ltd The Causeway Maldon Essex 9 4XD UK Installation Manual PPT8 12 16 22LX LY SLIMLINE 13 0 Contacting Email service calorex com Calorex Website http www calorex com 44 0 1621 857171 or 44 0 1621 856611 Please give MODEL NUMBER and SERIAL NUMBER of your heat pump when making technical or service enquiries This will assist in correct diagnosis and ensure service can be provided with the minimum delay Page 32 SD638153 ISSUE 10 Calorex Heat Pumps Ltd The Causeway Maldon Essex 9 4XD UK Installation Manual PPT8 12 16 22LX LY SLIMLINE 14 0 Machine Record Log In order to comply with European Union F Gas regulations it is necessary to leak test hermetically sealed systems with more than 6kg refrigerant annually The operator of the unit is responsible for seeing
26. three minutes each hour so that water is pumped through the heat pump If during this sampling period the heat pump detects a need for water heating it will continue to override the time clock until the swimming pool temperature is satisfied If water heating is not required the filter pump will turn off after the three minute sampling period and not restart the next hourly sampling period or time clock pre set run time This feature will reduce filter pump run time and consequently save energy as well as unnecessary filter pump wear and tear MAX RATING 3A HP AT 250V CALOREX HEAT PUMP CUSTOMERS EXTERNAL EXTERNAL COMPONENTS TO PUMP FILTER TIME CLOCK BE WIRED TO TERMINAL BLOCK LOCATED INSIDE POOL PUMP MACHINE ELECTRIC BOX STARTER A pair of volt free terminals numbered 14 and 15 are available to allow for the heatpump to be switched on or off remotely Page 15 SD638153 ISSUE 10 Calorex Heat Pumps Ltd The Causeway Maldon Essex 9 4XD UK Installation Manual PPT8 12 16 22LX LY SLIMLINE 5 0 Digital Thermostat An adjustable touch screen digital thermostat controls and maintains the water temperature and incorporates the indicator lamps Press and release the P key to display required temperature To alter required temperature press the up or down keys a gentle touch is all that is necessary After 5 seconds the display reverts to actual water temperature Not used S tecNOLOGic Increase Set Point Also
27. tment Telephone 44 0 1621 857171 or 856611 8 1 User Check List The thermostat displays the following lamps during normal operation SYMBOL DESCRIPTION LAMP ON LAMP FLASHING LAMP OFF HEAT PUMP IN DEFROST DEFROST WATER HEATING DEMAND NO DEMAND FOR WATER COMPRESSOR DELAY HEATING DEMAND TIMER NOT SATISFIED TIMED OUT DEMAND FOR WATER HEATING WATER HEATING FAN NOT RUNNING COMPRESSOR DELAY TIMER NOT TIMED OUT FAN RUNNING FAN NOT RUNNING POOL PUMP RUNNING OFF LAMP HEAT PUMP OFF POOL PUMP POOL PUMP NOT RUNNING If an error occurs any of the following lamps or messages will be display SYMBOL DESCRIPTION LAMP ON LAMP FLASHING ACTION AN AAALAC ILLUMINATES WITH CHECK WATER PUMP WATER FLOW WATER FLOW OFF WATER FLOW OFF OR RUNNING AND ANY LAMP OR INADEQUATE INADEQUATE EXTERNAL BYPASS VALVES ARE CLOSED CONTACT COMPETENT THERMAL INTERNAL ELECTRICIAN TO RESET OVERLOAD OVERLOAD TRIP THERMAL OVERLOAD IF PPT16 22 PROBLEM PERSISTS CHECK SITE VOLTAGE PRESSURE SWITCH ALARM HP LP FAULT CONSULT INSTALLER SYMBOL DESCRIPTION LAMP ON ACTION PROBE 1 1 INTERRUPTED CHECK CONNECTION BETWEEN PROBES AND E2 E2 PROBE ERROR SHORT CIRUIT OR THERMOSTAT OUTSIDE RANGE INTERNAL SWITCH OFF HEAT PUMP AT MAINS SUPPLY FOR EPr PROBE ERROR EEPROM MEMORY FIVE MINUTES THEN SWITCH BACK ON IF FAULT ERROR PERSISTS CONTACT INSTALLER Page 22 S
28. y Hz 47 5 52 5 This voltage must be made available at the heat pump while running T Note the Isolator must have a minimum of 3mm air gap when turned off NOTE Three phase heat pumps are fitted with a phase protection relay and will not run if the phases are not connected in the correct order phase sequence or if the supply voltage is 15 less than the nominal voltage 415V for 3N 50Hz The lamp on the phase rotation relay situated in the electric box is illuminated when the phases are correctly connected and the voltage is sufficient IMPORTANT The user should be made aware that THE WHOLE installation should be isolated when working on ANY PART Page 13 SD638153 ISSUE 10 Calorex Heat Pumps Ltd The Causeway Maldon Essex 9 4XD UK Installation Manual PPT8 12 16 22LX LY SLIMLINE 4 2 Location of Mains LOOSEN CAPTIVE SCREWS 6 ENSURE EARTH LEAD IS STILL CONNECTED AND LIFT COVER OFF Input and External T Interlock Terminals ELECTRIC ID MAINS IN SINGLE PHASE 230V 1 50Hz NN VOLT FREE POOL PUMP RUN TERMINALS X REMOTE ON OFF INTERLOCKS
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