Calorex Propac 90 User Manual (Swimming
Contents
1. 110 ou SV NI NOLLISOd OL 94130 INO 1 ld 589 08 LM a 1 nS aJ o 2 10 S3NIHOVIN NO HOLIMS JOYIS 19534 5 1no 7 HOLIMS 3 ss3oov e HOLIMS dH xog 25 amp 310SNOO 1 008 JL e S 062 1nO 5 999 32495 9 5 8 31 SNOLLO3NNOO H31VM STANVd OL 585400 009 MOTIV INSSI NI SNOISNAWIG 099 AW INOE NI NOILISOd 110 31VSN3QNOO 359 NOLLISOd ANIHOVW SYNOAS OL 110 OST 589 b r1 E NI UT 047 3 S3NIHOVIN2. REMOVE SERVICE PANEL 1 4 TURN FASTENERS 2 units have interlock circuit incorporated in control circuit brought out to two terminals These terminals are shorted out for factory testing The interlock may be used to control the heatpump from a remote location or a built in flow switch On site shorting loop is to be removed and two wires taken to pair of volt free contacts in water pump starter contactor relay or flow switch so that the Heat Pump cannot operate unless water pump is operating see figs 5 and 6 page 11 Fig 5 RECOMMENDED ELECTRICAL INSTALLATION FOR CALOREX HEAT PUMP WITH SINGLE PHASE WATER PUMP SWITCHED FUSE ISOLATOR WITHIN 2m OF HEAT PUMP AND SIZED INACCORDANCE WITH DATASHEET SINGLE PHASE CALOREX HEAT PUMP SUPPLY TO SUIT THREE PHASE CAPACITY OF WATER Pd ina 12 3 4 5 6 7 8 9 10 11 UN 90000090 N L1 L2 o c Lu E z fit L N 4 POLE N O STARTER WITH OVERLOAD 230V 50Hz COIL RATED TO SUIT WATER PUMP N L N WATER PUMP MORE THAN SINGLE PHASE Fig 6 RECOM
3. 30 45 70 90 140 UNITS HEATING kW 32 40 62 80 124 kW 7 8 9 75 14 4 19 5 29 kW 25 5 32 50 64 100 kW 7 3 8 12 5 16 25 kW 19 2 23 8 36 50 1 71 9 kW 5 98 7 67 10 96 16 17 21 93 V ph Hz 220V 3 60Hz 5 42 1 84 2 5 59 118 amps 205 205 amps 26 26 m hr 6300 12000 14000 24000 28000 mm WG 0 0 0 0 0 mm WG N A 4 5 6 4 5 6 L min 123 246 369 492 738 m hd 4 2 4 8 14 5 6 7 4 inches 1 BSPM 2 2 3 3 inches 1 BSPM 17 BSPM X2 1 BSPM X2 L min 133 266 m hd 3 9 5 3 inches 1 BSPM 2 BSPM kg 6 2 13 5 16 4 18 X2 15 X2 kg 15 X2 SCROLL SCROLL SCROLL 2xSCROLL 2x SCROLL AXIAL AXIAL AXIAL 2 AXIAL 2x AXIAL 62 64 68 73 71 mm 1555 1665 1810 2095 2240 mm 2210 mm 790 1060 1190 1190 1650 mm 1080 1310 1310 1330 1340 mm 1745 1845 1990 2295 2440 mm 900 1170 1300 1310 1770 mm 1250 1480 1480 1500 1505 2 Allow 500mm clearance to service panels 3 Minimum air temperature 7 C 4 Water to have correct balance pH 7 2 7 8 Free Chlorine 1 0 2 0 ppm Domestic 3 0 6 0 Commercial 5 Calorex reserve the right to change or modify models without prior notice 6 R407c Global Warming Potential GWP 1700 page 33 NOILISOd
4. NO HOLIMS 1 JOIAH3S 18534 1 gt a HOLIMS 21 HOLIMS dH 30435 8585300 1 10 O OIMLOATA NV 910 09 D Tt 1 062 E 110 9991 9 di T3NVd TVNOILdO 5 SNOILOANNOO H31VM STANVd 2 35 OL 88320 009 MOTIV INSSI NI SNOISN3WIG 09S T3NVd AW INOELdd 3OIAH3S page 35 OLEL 09 59 3SV8 NI NOILISOd 110 31VSN3QNOO 058 O CES 4460 Ln B 0901 3SV8 NI NOILISOd 110 31VSN3QNOO 7901 M3lVM 1no 0691 S991 a 051 H313WVIG o TANVd 21 5 34 035 OL S3HIN3O NI TANVd 3983 TANVd ADIAYAS SS Ss 55900 xog OIH 103T3 1 35 S3NIHOVIN NO HOLIMS 1953 0119 HOLIMS HOLMS dH 9 LNO 36
5. M31VM i ino B T3Nvd 5 i sil lt pr 1 0921 0181 TANVd SO0IAYAS TANVd S0IAYAS 91 8 yALAWNVIC IVNIINON ANIHOVW 3038 OL 5951399 TANVd AOIAYAS NI SNIVI HOLIMS p 399 onilod13 32835 310SNOO page 38 INdS8 31VSN3QNOO INdS8 9 SNOLLO3NNOO STANVd 39IAH3S OL 55900 WWOOS MOTIV V 3nssl NI SNOISN3WIG 02 NI NOILISOd 110 1 NOILISOd 110 998 du 986 rm 5 8 re9 o 5 4 5 ino lt 71 TANVd 0921 0181 TANVd 39IAH3S 5 8 SYNOAS OL 5951399 SNIXIJ SNIV
6. 1 TVNOILdO WdS8 SNOLLO3NNOO STANVd OL SS309V 303 MOTIV 8755 WW AW INSVdd 3SV8 NI NOILISOd 3SV8 NI NOILISOd 170 31VSN3QNOO 170 31VSN3QNOO 088 750 9 S86 1 O0 a 7 n SI ENGINES n O NI a L o a L H H Hi 1no E L L L L H 5801 4 0691 5991 051 HALAWVIG IVNINON TaNvd 3933 TANVd SOIANSS 34 035 OL S3HLIN3O 0 6 LOO I NI 3OIAH3S S3NIHOVIN NO HOLIMS 18538 0119 HOLMS d SS322V ESP 91319573 Du 39IAH3S 310SNOO LNO 01 5 31VSN3QNOO INdS8 SNOLLOSNNOO H3 1VM STANVd 3OIAH3S OL 53099 0 MOTIV INSSI NI SNOISN3INIG AWI INSVLdd OVdO ld page 37 NI NOILISOd 110 31VSN3 NOO NI NOILISOd INO 1 966 998 0001 02 0 I NI
7. 661 13 COMP TAUX VALVE COIL LIQUID LINE SHUT OFF STANDBY NIC N O RUN CIRCUIT 1 42 STANDBY COMP2 SWITCH CIRCUIT BREAKER RIP OFF CONTACT CONTACTOR FLOW OK LIGHT 6 NIC 5 6 0 13 e 4 NIC 4 E 2 NIC 1 2 RELAY 1 86 21 22 COMP 2 AUX co NC NiO SWITCH 1 4 COMP 2 AUX VALVE COIL LIQUID LINE SHUT OFF SOFT START CIRCUIT 2 THERMAL OLLOAD amp 53 FAULT LIGHT 7155 FITTED f STARTER OR SMINS EXTERNAL TIMER FLOW SWITCH pi FAN 2 THERMAL LIGHT CUT OUT NO L FAN 1 THERMAL m COMPRESSOR 1 CUT OUT Tic AUX BLK FAN2MCB las TRIP OFF BREAK AUX ALARM COMPRESSOR 2 MCB AUX BLK FAN 1 MCB 50 7 an AUX ALARM 33 TRIP OFF BREAK TRIP BREAK 074 NIC 3 9 DELAY TIMER 1 17075 12 HOUR 16 NIC 15 WNO RELAY ALL 9 6 NIC x 4 e ING ui 11 COM MAINS LIGHT NEUTRAL CONTROL CIRCUIT BREAKER mE page 18 ELECTRICAL CIRCUIT DIAGRAM PROPAC30BMY THREE PHASE 400V 3 N 50Hz CIRCUIT BREAKER COMPRESSOR CONTACT CONTACTOR 6 5 6 N O W1 4 3 4 NO
8. 2 AN DELAY TIMER 1 HEATER 12 HOUR A2 RELAY R2 15 18800 YY Al 2 6 NIC 14 1 NO Al A2 DELAY TIMER 2 S SMART CLOCK FEED TERMINALS FALLING DIGITAL STAT 1 STAGE MAKES 4 TO 6 ON TEMP 10 SENSOR 11 RUN N O 2 3 NIC STANDB WATER FLOW OK LIGHT STANDBY SWITCH om AW 4 RELAY R1 7 WATER FLOW SWITCH SOFT START THERMAL O LOAD amp FAULT LAMP IF U FITTED wd 54 95 STARTER OR EXTERNAL zz FLOW SWITCH EB LP SWITCH NIC L 1 H NO BREAKS TO ON PRESSURE FALLING COM HP SWITCH 4 BREAKS L ON PRESSURE RISING emit 04 FAN THERMAL CUT OUT TE NC TK COMPRESSOR MOTOR PROTECTOR NIC FAN MCB AUX BLK ALARM 96 46 95 COMPRESSOR MCB AUX ALARM 96 NIC TRIP BREAK CONTACT 95 LIQUID LINE SHUT OFF VALVE ww bid REVERSING VALVE a 9 DEFROST LIGHT 2 D AUX BLOCK 3 NIC At 2 63 64 COM 1 6 N O 4 1 2 FAN CIRCUIT BREAKER TRIP OFF BREAK CONTACT 2 N C 1 COM CONTROL CIRCUIT PHASE BREASER ROTATION TRIP OFF
9. 5 DIG STAT 1 STAGE 10 11 MAKES 6 TO 4 ON TEMP FALLING COM ES z N NIC STANDBY 34 2 RUN 1 d SWITCH FLOW OK LIGHT e N O RELAY R1 ware FLOWN SWITCH SOFT START THERMAL O LOAD amp FAULT LIGHT INTERLOCK TERMINALS STARTEROR EXTERNAL FLOW SWITCH m LP SWITCH FAULT BREAKS TO H ON 69 LIGHT PRESSURE FALLING L H NIC HP SWITCH duo BREAKS L ON COM PRESSURE RISING TK FAN THERMAL j NIC COMPRESSOR MOTOR PROTECTOR 49 MCB AUX BLK ALARM 96 TRIP BREAK CONTACT 95 COMPRESSOR MCB 96 AUX BLK ALARM 574 g5 N C TRIP BREAK CONTACT e MAINS LIGHT CONTROL PHASE L3 L2 L1 CIRCUIT BREAKER ROTATION RELAY NEUTRAL page 13 ELECTRICAL CIRCUIT DIAGRAM PROPAC 45BM THREE PHASE 400V 3 N 50Hz FAN CIRCUIT BREAKER TRIP OFF BREAK CONTACT 6 NIC CONTACTOR 5 8 4 NIC 3 L 4 2 1 1 _ 2 2 MCB SETTINGS COMPRESSOR COMP CIRCUIT BREAKER TRIP REAK CONTACT 6 NIC CONTACTOR 5 6 w1 4 3 1 4 V1 2 N C I 2 it 01 DELAY TIMER 2 2 5A 23 8A 17A MCB CONTACTS MCB ALARM CONTACTS MCB AUX CO
10. STANVd SA0IAYAS 303 WWO0S MOTIV 8755 WW 06 Ldd 0551 40 SYNOAS OL S3HIN3O SNIXIJ NOLLISOd 9191 31VSN3 NOO 0621 2991 3SV8 NI NOILISOd 8 9651 HOLIMS NI 1 TANVd 39IAH3S HOLIMS di xog d 4 35 269 9viz 0991 1 gt 0122 0977571 S18 T3NVd 3OIAMN3S JOINS 128 TANVd 39IAH3S 110 WdS8 ALVSNAGNOO SNOILOANNOO STANVd 4 45 303 INSSI ww NI SNOISN3WIG 071 41 SYNOAS OL S3HIN3O j 2991 3SV8 NI NOILISOd 110 1 9661 3SV8 NI NOILISOd 9191 110 ALVSNSGNO9 278 067 k T mae S3NIHOVIN S3NIHOVIN 8 lo A NI NO HOLIMS NO HOLIMS 13534
11. TEMP FALLING E REVERSING VALVE DEFROST LIGHT 3 Q ANIC A FAN CIRCUIT BREAKER TRIP OFF BREAK CONTACT 6 NIC CONTROL CIRCUIT BREAKER TRIP OFF BREAK 131211 CONTACT 6 4 2 CONTACTOR Q 2 1 ROTATION RELAY page 21 MCB SETTINGS CONTROL COMPRESSOR FAN 2 5A 46 8A 3 3A MCB CONTACTS MCB ALARM CONTACTS MCB AUX CONTACTS SHOWN WITH CIRCUIT BREAKER MANUALLY SWITCHED TO THE ON CONDITION WATER FLOW SWITCH CONTACTS SHOWN WITH WATER FLOW AT MAXIMUM RATE ALL OTHER CONTACTS SHOWN IN DE ENERGISED STATE BUT WITH REFRIGERATION CIRCUIT FULLY CHARGED WHERE CONTACTS ARE MARKED N O OR N C ON CIRCUIT DIAGRAM ABOVE CONDITIONS APPLY ELECTRICAL CIRCUIT DIAGRAM PROPAC 70BMY THREE PHASE 400V 3 N 50Hz COMPRESSOR COMPRESSOR CIRCUIT BREAKER CONTACTOR 6 5 6 w1 4 NIC 1 2 1 2 N 0 21 i 22 NIC DELAY TIMER 1 NN 12 HOUR HEATER AR A2 716 14 5 11 DELAY TIMER 2 z 2 SMART CLOCK FEED TERMINALS DIGITAL STAT 1 STAGE RUN N O 2 3 STANDBY WATER EMO OLIGHT STANDBY
12. 13534 olny 110 g HOLIMS 4 5 HOLIMS 5 m Xog 2141019 HOLIMS NI NI HIY TANVd L c ko N 92 T 110 059 gt 1244 9 TANVd 5 09227 YALANVIG lt TANVd 5 WdS8 SLVSNSGNOO TVNOI LdO Y3LYM STANVd 3OIANH3S 303 3AV31 INSSI ww NI SNOISN3NNIG AW INOT TANVd 39IAH3S WINTERISATION PROCEDURE WARNING Isolate machine before opening As heat pump embodies electrical and rotational equipment it is recommended for your own safety that a competent person carries out the following procedure Drain Down Procedure ALL MODELS Object To provide frost protection to eliminate corrosion problems To inhibit electrical components 1 Switch off electrical 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 a drain valve if fitted b disconnecting pipework to and from heat pump c Note that where there is more than one condenser there will be multiple drain down points all of which need to be opened 5 Flush through water circuit
13. COMP AUX NC 13 14 LIQUID LINE SHUT OFF VALVE 4 5 COMP AUX 8 NO RELAY R2 zi DELAY TIMER 1 8 12 HOUR NIC L H DEFROST 69 LIGHT DEFROST c die STAT p BREAKS TO H ON TEMP FALLING SMART CLOCK FEED TERMINALS SENSOR NIC 5 DIG STAT 1 STAGE MAKES 6 TO 4 ON TEMP FALLING STANDBY LIRUN 2 1 COM SWITCH FLOW OK LIGHT N O 4 Q STANDBY N C 3 COM 7 1 N C 4 WATER FLOW A B SWITCH RELAY R1 SOFT START THERMAL O LOAD amp _ FAULT LIGHT IF INTERLOCK STARTER TERMINALS OR EXTERNAL FLOW SWITCH 1H N O LP SWITCH BREAKS TO H ON C COM 69 FAULT LIGHT PRESSURE FALLING HNIC D HP SWITCH BREAKS TO L ON COM PRESSURE RISING FAN THERMAL TK CUT OUT FAN MCB AUX 96 BLK ALARM j TRIP BREAK CONTACT 95 COMPRESSOR MCB 44 AUX BLK ALARM TRIP BREAK CONTACT e MAINS LIGHT L3 L2 L1 CONTROL CIRCUIT BREAKER PHASE ROTATION RELAY NEUTRAL page 16 MCB CONTACTS MCB ALARM CONTACTS MCB AUX CONTACTS SHOWN WITH CIRCUIT BREAKER MANUALLY SWITCHED TO THE ON CONDITION WATER FLOW SWITCH CONTACTS SHOWN WITH WATER FLOW AT MAXIMUM RATE ALL OTHER CONTACTS SHOWN IN DE ENERGISED STATE BUT WITH REFRIGERATION C
14. 01621 857171 or 856611 MAINS FAULT DEFROST WATER FLOW MAINS FAULT DEFROST WATER FLOW MAINS FAULT DEFROST WATERFLOW MAINS FAULT DEFROST WATERFLOW MAINS FAULT DEFROST WATERFLOW MAINS RED FAULT AMBER DEFROST WHITE WATERFLOW GREEN USER CHECK LIST 30 45 70BM UNIT OPERATES INTERMITTENTLY ON ON OFF OFF ACTION UNIT DOES NOT OPERATE Check mains supply external fuses isolator etc Water flow inadequate Check water pump to restore water flow through machine Check waterflow rate Check internal control MCB Check thermostat set point 12 hour timer timing out or standby switch set to 0 Check air flows are not restricted Check thermal cut out on Soft Start if fitted Check HP LP cutout switch and reset red button below console thermostat NOTE LP Switch is Auto reset on Y machines Check Fan and compressor overloads Fan located in electric box FAN ON COMPRESSOR OFF Unit on defrost normal if after 20 mins the defrost lamp is still on check that air temperature is not below 10 C for M models 15 C for models Check evaporator is clean Check 12 hours elapsed since first power up Check water flow is not restricted and that electrical supply is adequate Check that linked in external equipment is not the cause of the fault page 27 5 FAULT FRIDGE FAULT 1 AND OR 2 DEFROST WATER FLOW MAINS FAULT
15. FRIDGE FAULT 1 AND OR 2 DEFROST WATER FLOW MAINS FAULT FRIDGE FAULT 1 AND OR 2 DEFROST WATERFLOW MAINS FAULT FRIDGE FAULT 1 AND OR 2 DEFROST WATERFLOW MAINS FAULT FRIDGE FAULT 1 AND OR 2 DEFROST WATERFLOW MAINS FAULT FRIDGE FAULT 1 AND OR 2 DEFROST USER CHECK LIST 90 140BM ACTION UNIT DOES NOT OPERATE Check mains supply external fuses isolator etc Water flow inadequate Check water pump to restore flow through machine Check waterflow rate check internal control MCB Check thermostat set point Check internal control M C B 12 hour timer timing out or standby switch set to 0 Check air flows are not restricted Check HP LP cut out switch and reset red buttons NOTE LP Switch is Auto reset on Y machines Fridge CCT 1 cut out switches in LH side of machine electric box facing Fridge CCT 2 cut out switches mounted below console Check compressor motor circuit breakers Check Compressor thermal overloads Check fan motor circuit breakers Check soft start if fitted Check linked in external equipment is not the cause of the fault Check water flow is not inadequate and water pump etc to restore flow to machine page 28 UNIT DOES NOT OPERATE MAINS FAULT FRIDGE FAULT 3 1 AND OR 2 Check Thermal motor starters for fans have not tripped Check soft start has not tripped if fitted Check external flow switch is made if fitted DEFROST
16. SWITCH COM 4 5 0 4 1 RELAY R1 COM 7 WATER FLOW SWITCH SOFT START THERMAL O LOAD amp n ve FAULT LAMP IF FITTED z STARTER OR EXTERNAL FLOW gu SWITCH LP SWITCH BREAKS TO H ON NIC L 1 H N O PRESSURE FALLING COM HP SWITCH f J BREAKS TO L ON PRESSURE RISING 62 FAULT LIGHT FAN THERMAL TK NC CUT OUT TK FAN MCB 96 ALARM 96000 95 COMPRESSOR 44 NIC MCB ALARM mw 43 LIQUID LINE SHUT OFF VALVE 2 4 REVERSING VALVE Q Qiu fir 2 DEFROST LIGHT 3 E 4 COMP e CONTACTOR oz we AUX 8 BLOCK ET 4 NIC T COM 13 1 6 4 3 4 2 1 2 22 FAN CIRCUIT BREAKER CONTACTOR EM 12 4 NIC T 1 2 NIC COM CONTROL CIRCUIT PHASE ROTATION BREAKER RELAY MAINS LIGHT 131211 e NEUTRAL page 22 MCB SETTINGS COMPRESSOR 39 34 CONTROL 25A FAN 27A MCB CONTACTS MCB ALARM CONTACTS MCB AUX CONTACTS SHOWN WITH CCT BREAKER MANUALLY SWITCHED TO THE ON CONDITION WATER FLOW SWITCH CONTACTS SHOWN WITH WATER FLOW AT MAXIMUM RATE ALL OTHER CONTACTS SHOWN IN DE ENERGISED STATE BUT WITH REFRIGERATION CIRCUIT FULLY CHARGED WHERE CONTACTS ARE MARKED N O OR N C ON CCT DIAGRAM ABOVE CONDITIONS APPLY ELECTRICAL CIRCUIT DIAGRAM PROPAC 140BMY THREE PHASE 400V 3 N 50Hz
17. 5Hz 52 5 2 Three phase machines 60 2 187V 253V Cycle frequency 60 2 57 0 2 63 2 This voltage must be made available at heat pump whilst running T Note the isolator must have a minimum of 3mm air gap when turned off NOTE All machines are fitted with a phase protection relay and will not run if the phases are not connected in 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 The undervoltage protection feature is not present in phase protection relays fitted in 220V 3 60Hz machines When the machine is started for the first time it is vital that the 12 hour delay incorporated into the compressor is allowed to occur This delay prevents damage to the compressor which would be expensive to repair After this initial start up the machine can be turned on and off by use of the standby switch It should be noted however that when on standby the machine is still live page 10 Fig 4 LOCATION OF MAINS INPUT AND EXTERNAL INTERLOCK TERMINALS SOFT SMART FLOW D N U 12 13 START CLOCK SWITCH Q MAINS SUPPLY IN Interlock E
18. 67 Recommended Supply Fuse 3 Phase amps 30 35 50 70 100 Max Starting Current STD LRA amps 80 102 174 102 174 Max Starting Current S Start LRA amps 31 34 40 34 40 AIR DATA Nominal Air Flow m hr 6300 12000 14000 24000 28000 Fan External Resistance mm WG 0 0 0 0 0 Fan External Resistance mm WG N A 4 5 6 4 5 6 WATER DATA PPT PROPACS Water Flow 10 L min 123 246 369 492 738 Pressure Drop Water m hd 4 2 4 8 1 4 5 6 7 4 Water Connections inches 177 BSPM 2 BSPM 2 BSPM 3 BSPM 3 BSPM Condensate Water Connections 1 BSPM 1 BSPM Optional Factory Fit ALL inches _ 1 2 2 WATER PROPACS Water 10 L min 133 266 Pressure Drop Water m hd 3 9 5 3 Water Connections inches 12 BSPM 2 BSPM GENERAL DATA Hermetic System Gas Charge R407c PPT PROPACS kg 6 2 13 5 16 4 18 X2 15 X2 Gas Charge R407c PP PROPACS kg 17 20 5 15 X2 Compressor Type SCROLL SCROLL SCROLL 2xSCROLL 2xSCROLL Fan Type AXIAL AXIAL AXIAL 2x AXIAL 2x AXIAL Sound Pressure Level 3m dBA 62 64 68 73 71 DIMENSION DATA Width unpacked mm 1555 1665 1810 2095 2240 Width unpacked mm 1555 2210 Depth unpacked mm 790 1060 1190 1190 1650 Height unpacked mm 1080 1310 1310 1330 1340 Width export packed mm 1745 1845 1990 2295 2440 Depth export packed mm 900 1170 1300 1310 1770 Height export packed mm 1250 1480 1480 1500 1505 NOTES 1 Weight and Dimensions Nett 2 Allow 500mm clearance t
19. ALARM CONTACTS MCB AUX CONTACTS SHOWN FRIDGE WITH CIRCUIT BREAKER MANUALLY SWITCHED TO THE ON CONDITION CIRCUIT 2 RELAY R3 121 HNO FRIDGE CIRCUIT 1 DEFROST N C BREAKS TO HN O FIG 1 1 7 COM Faune COM T 1 J 7 NS 3 9 COM SEEFIG 1 6 7 rye 3 4 7 He 9 RELAY RELAY FIG 1 RELAY R2 FRIDGE FRIDGE CIRCUIT 1 COMP LP SWITCH H N O H N O BREAKS ON PRESSURE C COM BREAKS TO FALLING PRESSURE FALLING CIRCUITS FAULT FRIDGE Q SANT FRIDGECIRCUMT A 1 LIGHT cue NIO L H NIC EIGHT CIRCUIT BREAKER SWITCH COM TRIP OFF BREAK CONTACT CONTACTOR PRESSURE RISING BREAKS TO L ON 5 5 1600 PRESSURE RISING 4 No 1 200 FAN 2 CIRCUIT BREAKER FAN2 43 TRIP OFF BREAK CONTACT CONTACTOR COMP 1 MCB AUX BLK N O Compe 5 6 NiO TRIP OFF BREAK TRIP OFF BREAK nali CONTACT CONTACT ey 1 2 A LUN COMP 1 CIRCUIT BREAKER TRIP OFF BREAK CONTACT CONTACTOR 6 NIC 5 m 6 53 SMART CLOCK FEED TERMINALS 4 NIC 4 2 NIC 1 2 2 MAKES 6 TO 4 ON 21 2 10 2 N OUT De GE TEMP FALLING 10 COMP 1 AUX
20. HP SWITCH L BREAKS TO L ON PRESSURE RISING FAN THERMAL CUT OUT COMPRESSOR MOTOR PROTECTOR FAN MCB AUX BLK ALARM RELAY R1 WATER FLOW SWITCH ES 53 1 COM LIGHT 2 CONTROL CIRCUIT PHASE BREAKER TRIP OFF BREAK ROTATION CONTACT RELAY TRIP BREAK CONTACT COMPRESSOR MCB AUX BLK ALARM TRIP BREAK 95 LIQUID LINE SHUT OFF VALVE 2 lt N 58 REVERSING VALVE 9 05 fitz 2 DEFROST LIGHT gt 3 Q COMP AUX BLOCK 4 NIC 63 64 COM 1 6 5 6 4 4040 2 1 2 FAN CIRCUIT BREAKER TRIP OFF BREAK CONTACT FAN CONTACTOR 6 12 NIC 4 11 MAINS LIGHT e 131211 NEUTRAL page 20 MCB SETTINGS CONTROL COMPRESSOR FAN 2 5A 23 8A 1 7A MCB CONTACTS MCB ALARM CONTACTS MCB AUX CONTACTS SHOWN WITH CIRCUIT BREAKER MANUALLY SWITCHED TO THE ON CONDITION WATER FLOW SWITCH CONTACTS SHOWN WITH WATER FLOW AT MAXIMUM RATE ALL OTHER CONTACTS SHOWN IN DE ENERGISED STATE BUT WITH REFRIGERATION CIRCUIT FULLY CHARGED WHERE CONTACTS ARE MARKED N O OR N C ON CIRCUIT DIAGRAM ABOVE CONDITIONS APPLY E
21. OFF BREAK CONTACT eon 5i 5 6 NO Wi IE at 4 NIC Ei 2 NIC 8 FRIDGE 1 FRIDGE CCT 2 t LP SWITCH LP SWITCH BREAKS TO H BREAKS ONPRESSURE N C ON PRESSURE N C LI FALLING FALLING 1 63 i 64 pw FRIDGE CCT 1 FAULT FRIDGECCT2 HP SWITCH HP SWITCH FAULT LIGHT FRIDGE CCT 1 BREAKS TO L H NIC BREAKS N O Ly J NIC A LIQUID LINE SHUT OFF ON PRESSURE ON PRESSURE VALVE COIL TRIP OFF comp 2 COMPRESSOR 2 BREAK CONTACT CONTACTOR COMPRESSOR 1 96 NIC MCB AUX BLK 96 NIC SIND i MCB AUX BLK 95 TRIP BREAK CONTACT 95 T 2 5 hi TRIP BREAK CONTACT pA NIC 4 NO 25 hhh 2 NIC 1 2 01 55 5 SMART CLOCK FEED TERMINALS 63 64 AUX 10 BER 71 LIQUID LINE SHUT OFF 5 z s DIGITAL STAT 1 STAGE VALVE COIL S B 2 RUN 2 NIC STANDBY gS COM 1 STANDBY FLOW OK LIGHT 28 SWITCH 9 Es Eis sav lt 5 9 gt s COMPRESSOR 2 MCB 54 NIC AUX BLK Ei WATER FLOW TRIP OFF BREAK SWITCH CONTACT BREAKS ON WATER FLOW RATE FALLING eje TM 515 SOFT START 5 5 THERMAL r3 3g O LOAD amp mjt ug FAULT LAMP IF ee FITTED 53 xz STARTER OR zz 5 EXTERNAL FLOW SWITCH E lt COMPRESSOR 1 MOTOR PROTECTOR COMPRESSOR2 MOTOR FRETEGTO
22. Refrigerant Removals Reason for removal What done with recovered Date Engineer Amount Removed kg 2273 Name refrigerant pT pues Leak Tests Test Result Follow up action required Follow up Actions Engineer Date Engineer Related to test on Actions tak Related to teston ee Testing of Automatic Leak Detection System if fitted 1 Name and address of company operating plant Contact details for operators nominated person responsible for Gas compliance 3 Company and technician carrying out work with details to provide evidence of compliance page 45
23. WATERFLOW FAN ON COMPRESSOR OFF MAINS FAULT FRIDGE FAULT Unit on normal defrost If after 20 mins defrost lamp is still on check that 1 AND OR 2 air temperature is not below 10 C for M models 15 C for MY models DEFROST Check 12 hours elapsed since first power up WATERFLOW UNIT OPERATES INTERMITTENTLY MAINS ON Check water flows are not restricted FAULT ON OFF and that electrical supply is adequate FRIDGE FAULT 1 AND OR 2 OFF Check that linked in external equipment is not the cause of the fault DEFROST OFF WATERFLOW ON OFF page 29 DATA SHEET AIR TO WATER HEAT PUMPS FOR SWIMMING POOL AND HOT WATER APPLICATIONS 400 3N 50Hz UNITS BM PROPAC PROPAC PROPAC PROPAC PROPAC model 30 45 70 90 140 UNITS DUTY Air On 20 C 65 RH HEATING Output To Water 26 C kW 32 40 62 80 124 Electrical Input kW 7 8 9 75 14 4 19 5 29 ELECTRICAL DATA Electrical Supply 3 Phase V ph Hz 400V 3N 50Hz Minimum Supply Capacity 3 Phase amps 20 22 35 43 67 Recommended Supply Fuse Phase amps 30 30 50 60 100 Max Starting Current STD LRA amps 80 96 174 96 174 Max Starting Current S Start LRA amps 31 33 40 33 40 AIR DATA Nominal Air Flow m hr 6300 12000 14000 24000 28000 Fan External Resistance mm WG 0 0 0 0 0 Fan External Resistance mm WG N A 4 5 6 4 5 6 WATER DATA PPT PROPACS Water Flow 10 L min 123 246 369 492 738 Pres
24. approved page2 THE HEAT PUMP CYCLE 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 ambient air pre heated by the sun In the Calorex swimming pool heat pumps high volumes of outside air are drawn into the unit by the fan expelled through the evaporator fins The evaporator has liquid refrigerant passing through it Which is at a considerably lower temperature than the ambient air Therefore the air gives up its heat to the refrigerant which then vaporizes This preheated vapour now travels to 2 THE COMPRESSOR where it is compressed and upgraded to a much higher temperature The hot vapour now enters lt WATER OUT HEAT EXCHANGER EVAPORATOR WATER IN COLD LIQUID REFRIGERANT 4 CONDENSED 4 mr REFRIGERANT b EXPANSION HIGH PRESSURE SIDE VALVE LOW PRESSURE SIDE 3 THE CONDENSER where it is surrounded by the pool water the heat is 4 THE EXPANSION DEVICE and from given up to the cooler pool water and the there now at normal pressure it is returned now cold refrigerant returns to its former to the evaporator and the cycle starts again liquid state but still under high pressure from Note that during t
25. handle and lock off valve C page 8 5 0 ELECTROLYTIC CORROSION IN SWIMMING POOLS Electrolytic corrosion will occur when dissimilar metals that are in contact 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 A swimming 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 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
26. in heat pump by using CLEAN TAP WATER NOT POOL WATER via hose into outlet connection run for 10 minutes minimum use spray nozzle if available Allow to drain fit plastic bags secured by elastic bands over water connections Uncover electrical enclosure see page 7 fig 4 and liberally spray interior of unit with moisture repellant aerosol WD 40 or similar reseal enclosure If heat pump located outside protect from weather by covering with VENTILATED cover Do not use plastic sheet as condensation can occur within unit N B If this procedure is not adopted and frost or corrosion damage results then the warranty will become invalid START UP PROCEDURE AFTER WINTERISATION 1 Replace covers if not fitted 5 2 Remove front grille using soft 6 brush clean finned surfaces of heat pump Replace panel 3 Remove plastic covers water connections and reconnect water 8 piping or close drain valve 4 Start up water circulating pump and leave running for at least 1 4 hour to 9 establish flow and enable any air in system to escape page 43 Replace fuses to heat pump circuit Switch on heat pump Check control thermostat is set to required pool temperature Check daily to ensure pool water is at correct pH and has correct chemical balance See Section 3 Plumbing Note that the compressor will not start until after a delay of 12 hours This allows time for the compressor to warm up and
27. which may not be protected by this system page 9 5 1 ELECTRICAL MACHINE WIRING AND SUPPLY SEE FIG 4 5 and 6 FOR PREFERRED METHOD The cable supplying electricity to a machine with a given load must increase in cross sectional area C S A as the length increases in order that the voltage drop within the cable does not exceed recommended limits Cable sizing should be calculated by an appoved electrician All electrical work to be carried out in accordance with standards latest issue or local codes of practice as applicable The machine should be installed in accordance 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 this heat pump and any associated equipment When fitting recommended earth leakage trip to avoid nuisance tripping the machine should be connected to its own 30mA trip separate from any other associated equipment 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 Voltage Minimum Maximum Three phase machines EU 360V 440 Cycle frequency 50 2 47
28. 182 no 53 no 5 gt 13i 14 nevn 2 0 20 Don 58 58 mS 94 94 92 FRIDGE CCT 1 LIQUID LINE SHUT OFF n VALVE COIL o E 2 Is CCT BREAKERTRIP COMP 2 MAKES 1703 GN CONTACTOR lo 5 6 N O DEFROST STAT 2 FRIDGE CCT 1 COM 1 HEATER 4 N C MAKES 1 3 ON TEMP FALLING DEFROST STAT FRIDGE CCT 2 13 14 NiO AUX FRIDGE CCT 1 LP SWITCH H LP SWITCH LINE SHUT OFF BREAKS TO NIC ld BREAKS L H N O VAVE ON PRESSURE FALLING ON PRESSURE FALLING 1 2 COMPRESSOR 2 MCB AUX FAULT LIGHT picis FAULT LIGHT TRIP OFF BREAK CONTACT BREAKS TO LN O H 4 H NIC A BREAKS TO NO Lp ON PRESSURE C COM ON PRESSURE RISING COM OMPRESSOR 1 MCB l gt COMPRESSOR 2 MCB 2 BLK nf 44 NIC AUX BLK mf 44 NIC 5 5 OFF BREAK 43 TRIP OFF BREAK CONTACT 43 CONTACT s Boc 18 3 5 a sl 92m 85 SMART CLOCK a FEED TERMINALS OUT 10 1 5 4 6 SLSENSOR TEMP FALLING T x e DIGITAL STAT 1 STAGE RUN 2 STANDBY 023 MCB STANDBY swore FLOW OK LIGHT 33 TRIP OFF BREAK 2 CONTACT 2 Am L 5 sk 5 E E 2 ERI 33 25 WATER FLOW SW
29. ACT K 5 69 FAULT LIGHT A 6 4 2 14 CONTROL CIRCUIT BREAKER PHASE ROTATION RELAY 12 L1 Q MAINS LIGHT 14 NEUTRAL ELECTRICAL CIRCUIT DIAGRAM 45EM THREE PHASE 220 3 60 2 TRIP BREAK CONTACT CONTACTOR N C 5 6 NO 3 4NO N C 1 2 A1 A2 COMP CIRCUIT BREAKER TRIP OFF BREAK CONTACT CONTACTOR 6 N O w1 4 N O v4 _ 2 01 111 RELAY R2 A2 22 COMP AUX NIC LIQUID LINE SHUT 13 14 COMP AUX N C DEFROST Q LIGHT DEFROST c STAT BREAKS TO H TEMP FALLING SMART CLOCK FEED TERMINALS 5 DIG STAT 1 STAGE MAKES 6 TO 4 ON TEMP FALLING 10 11 MAINS LIGHT 7 0 STANDBY SWITCH NO STANDBY N C 3 N O 4 FLOW OK LIGHT COM 7 1 N C 9 mv WATERFLOW A B SWITCH RELAY 81 SOFT START THERMAL O LOAD amp FAULT LIGHT IF INTERLOCK STARTER TERMINALS OR EXTERNAL FLOW SWITCH NIC L 1H N O LP SWITCH PRESSURE FALLING JH NIC HP SWIT
30. BREAK CONTACT RELAY FAN CONTACTOR MAINS LIGHT 131211 e 19 MCB SETTINGS CONTROL COMPRESSOR FAN 2 5A 229A 0 8 MCB CONTACTS MCB ALARM CONTACTS MCB AUX CONTACTS SHOWN WITH CIRCUIT BREAKER MANUALLY SWITCHED TO THE ON CONDITION WATER FLOW SWITCH CONTACTS SHOWN WITH WATER FLOW AT MAXIMUM RATE ALL OTHER CONTACTS SHOWN IN DE ENERGISED STATE BUT WITH REFRIGERATION CIRCUIT FULLY CHARGED WHERE CONTACTS ARE MARKED OR ON CIRCUIT DIAGRAM ABOVE CONDITIONS APPLY NEUTRAL ELECTRICAL CIRCUIT DIAGRAM PROPAC 45BMY THREE PHASE 400V 3 N 50Hz COMP CIRCUIT BREAKER COMPRESSOR TRIP OFF BREAK CONTACT CONTACTOR 6 5 6 1 4 3 4 V1 2 1 2 01 21 22 DELAY TIMER 1 HEATER 12 HOUR LV A2 RELAY R2 15 18 0 wn A2 16 NIC 14 2 A A1 A2 DELAY TIMER 2 SMART CLOCK 4 5 NIC OUT 4 16 2 N MAKES 4 TO 6 ON TEMP FALLING DIGITAL STAT 1 STAGE FEED TERMINALS SENSOR RUN 2 3 STANDBY WATER FLOW LIGHT A e STANDBY SWITCH COM 1 N O 4 7 SOFT START THERMAL O LOAD amp r1 FAULT LAMP IF FITTED STARTER OR EXTERNAL FLOW SWITCH LP SWITCH BREAKS TO H ON PRESSURE FALLING
31. CH BREAKS TO L ON PRESSURE RISING FAN THERMAL TK CUT OUT COMPRESSOR MOTOR PROTECTOR FAN MCB AUX BLK 96 ALARM TRIP BREAK CONTACT 89 COMPRESSOR MCB AUX BLK ALARM TRIP BREAKCONTACT 43 BREAKS TO H ON C COM 69 FAULT LIGHT 5 6 NIC 3 4 NIC 1 2 NIC CONTROL CIRCUIT PHASE 13 L2 L1 BREAKER ROTATION RELAY TRIP OFF BREAK CONTACT page 15 MCB SETTINGS CONTROL COMPRESSOR FAN 2 5A 46 8A 3 3A MCB CONTACTS MCB ALARM CONTACTS MCB AUX CONTACTS SHOWN WITH CIRCUIT BREAKER MANUALLY SWITCHED TO THE ON CONDITION WATER FLOW SWITCH CONTACTS SHOWN WITH WATER FLOW AT MAXIMUM RATE ALL OTHER CONTACTS SHOWN IN DE ENERGISED STATE BUT WITH REFRIGERATION CIRCUIT FULLY CHARGED WHERE CONTACTS ARE MARKED N O OR N C ON CIRCUIT DIAGRAM ABOVE CONDITIONS APPLY ELECTRICAL CIRCUIT DIAGRAM PROPAC 70BM THREE PHASE 400V 3 N 50 2 CIRCUIT BREAKER REAK CONTACT CONTACTOR 5 6 3 1 4 N O 2 N O A1 A2 hi CIRCUIT BREAKER MCB SETTINGS CONTROL COMPRESSOR FAN 2 5A 36 8A 2 7 TRIP OFF BREAKCONTACT CONTACTOR N C 5 6 4 3 gt 4 vi 1 2 01 5 DELAY TIMER 2
32. Cl Range 3 0 6 0 ppm Commercial Ozone 0 9 Max ppm Bromine 2 5ppm Baquacil 25 50 ppm Aquamatic lonic Purifier Max 2 ppm Copper 3 Maximum pressure of water in heat pump circuit should not exceed 3 50 psi page 7 4 DETERMINING WATER FLOW The Propac is fitted with a water flow switch which inhibits the operation of the machine when the minimum water flow is below 5000 I hr 2 lt 2 Y 5 gt za Se D5 LL 20 Ole amp 2 0 2 lt nO 2 lt 0 1 out gt 20 Tim gt m 5 D i m zu 2 X gH x lt OOE x Qi _ gt gt gt 5 lt gt 9 uoo 2 OTIO 45 Sad LU H gt 2 Sgr 9 8 245 9 IL 9 gt aN ongu 7 gt z 520 gt Fig 3 Flow Meter Method see fig 3 Ensure isolation valves and and bypass valve are fully open Close the bypass valve until the flow light that is positioned on the heat pump console illuminates and then close it slightly more to allow for flow loss due to a dirty filter Remove
33. IN NI HV en aH TANVd SOMES 310 09 100 INdS8 31VSN3QONOO TWNOILdO INdS8 SNOILOANNOO STANVd JOYIS 83099 303 00 MOTIV INSSI NI SNOISN3INIG OLldd P 31VSN3QNOO asya NOILISOd aivsnaanoo 281 186 9 NI HIY 4 E352 HOLIMS dH JIOSNOO h HOLIMS 899599 o oct LNO 0 1 Seva NI NOLLISOd 6601 E ud 3NIHOVIA ONINNOAS S3HIN3O NI NOILISOd SLVSNS0NO9 9011 NI H p 110 H gue if HOLIMS TNvS ZN Te gt 9002 9602 T L J E ul 897 EE ES 2 TANVd GF Se iS s TANVd 3943 024 YALAWVIG NVA O6LL SALVSNAGNOO IWNOILdO WdS4 SNOILOANNOO
34. IRCUIT FULLY CHARGED WHERE CONTACTS ARE MARKED N O OR N C ON CIRCUIT DIAGRAM ABOVE CONDITIONS APPLY ELECTRICAL CIRCUIT DIAGRAM PROPAC 90BM THREE PHASE 400V 3 N 50 2 COMPRESSOR COMPRESSOR FAN FAN CONTROL 1 2 1 2 25 23 8A 23 8A 17A 17A MCB CONTACTS MCB ALARM CONTACTS MCB AUX CONTACTS SHOWN WITH CIRCUIT BREAKER MANUALLY SWITCHED TO THE ON CONDITION WATER FLOW SWITCH CONTACTS SHOWN WITH WATER FLOW AT MAXIMUM RATE ALL OTHER CONTACTS SHOWN IN DE ENERGISED STATE BUT WITH REFRIGERATION CIRCUIT FULLY CHARGED RELAY R5 WHERE CONTACTS ARE MARKED N O OR NIC ON CIRCUIT DIAGRAM ABOVE CONDITIONS APPLY DEFROST RELAY R3 69 Lamp FAN 1 CIRCUIT BREAKER TRIP OFF FAN 1 FRIDGE CCT 2 BREAK CONTACT CONTACTOR DEFROST BREAKS TO H H N O NIC 5 6 ON C COM Hi Te TEMPERATURE FRIDGE CCT 1 FALLING DEFROST BREAKSTO H H N O COM TEMPERATURE FALLING RELAY R4 FAN2 CIRCUIT BREAKER FAN2 TRIP OFF BREAK CONTACT CONTACTOR 5 6 3 4 0 1 2 Nm 2 i 1 CIRCUIT BREAKER COMP 1 TRIP
35. ITCH 5 BREAKS ON WATER FLOW RATE FALLING SOFT START m THERMAL da amp FAULT LAMP E IF FITTED 25 STARTER OR 28 EXTERNAL oR FLOW SWITCH FAN 2 THERMAL TK FAULT CUT OUT LUSH A FAN 1 THERMAL TK CUTOUT FAN 2 MCB AUX ALARM 96 95 FAN 1 MCB AUX BLK ALARM n DELAY TIMER 1 TRIP BREAK CONTACT 12 HOUR COM 15 16 NO T8 NTO a A 2 11 CONTROL CIRCUIT BREAKER TRIP OFF BREAK CONTACT RELAY HGH 13 L2 L1 NEUTRAL page 23 REGULAR PLANNED MAINTENANCE Operations to be carried out during a regular planned maintenance visit are as follows Replace all belts where fitted Clean or replace filters as applicable This action may be required more frequently than regular servicing Check operation and condition of all fans and compressors Check capacitor tolerances where fitted Check condition of all heat exchangers evaporators Check refrigeration system parameters Check operation of control valves Check for water leaks Check drip trays and internal drain lines for blockages and clear Check operation of controls and calibrate as necessary Check operation of interlocks in use Final check on overall operation of unit Indicate on report any faults found or causes for concern Frequencies recommended Light to medium use 2 visits per year Heavy use 4 visits pe
36. LECTRICAL CIRCUIT DIAGRAM PROPAC 45EMY THREE PHASE 220V 3 60Hz come CIRCUIT BREAKER TRIP OFF BREAK CONTACT CONTACTOR t N 1 2 COM DIGITAL STAT 1 STAGE N C 57 640 Wi N C 4 1 N C 1 2 0 01 21 22 NIC ANN DELAY TIMER 1 HEATER 12 HOUR A2 RELAY R2 15 18 Al A2 16 14 2 11 pip At A2 DELAY TIMER 2 SMART CLOCK FEED TERMINALS MAKES 4 TO 6 ON TEMP FALLING SENSOR 11 MAINS LIGHT f RUN N O 2 1 1 STANDBY 3 0 4 SWITCH FLOW OK LIGHT 1 WATERFLOW SWITCH RELAY R1 SOFT START THERMAL O LOAD amp FAULT LIGHT IF FITTED STARTER emi EXTERNAL FLOW NL SWITCH BREAKS TO H ON PRESSURE FALLING NOL HP SWITCH fe PRESSURE RISING CUT OUT COMPRESSOR MOTOR PROTECTOR FAN MCB AUX BLK ALARM TRIP BREAK CONTACT COMPRESSOR MCB AUX BLK ALARM TRIP BREAK CONTACT INTERLOCK TERMINALS NIC L 1H N O LP SWITCH Je COM FAN THERMAL TK TK 69 FAULT LIGHT H N C A BREAKS TO L ON NIC LIQUID LINE SHUT OFF VALVE SY DEFROST STAT COMP CONTACTOR AUX 1 MAKES 1 3
37. MENDED ELECTRICAL INSTALLATION FOR CALOREX HEAT PUMP WITH THREE PHASE WATER PUMP SWITCHED FUSE ISOLATOR WITHIN 2m OF HEAT PUMP AND SIZED IN ACCORDANCE WITH SHEET HEAT PME THREE PHASE THREE RHASE SUPPLY TO SUIT CAPACITY OF WATER PUMP 12 3 4 5 6 78 9 10 11 Bu N L1 L2 L3 o m Lu E L3 12 L1 4 POLE STARTER WITH OVERLOAD AND 230v 50Hz COIL RATED WATER PUMP N L1 12 12 ELECTRICAL CIRCUIT DIAGRAMS ELECTRICAL CIRCUIT DIAGRAM PROPAC 30BM THREE PHASE 400V 3 50Hz FAN CIRCUIT BREAKER OFF BREAK CONTACT CONTACTOR 5 6 3 4 1 2 1 2 COMP CIRCUIT BREAKER TRIP OFF BREAK CONTACT MCB SETTINGS CONTACTOR 6 5 6 NO W1 E CONTROL COMPRESSOR FAN 4 3 4 Vi we Ue E 2 5A 22 9A 0 8A 2 N C 1 2 U1 a DELAY TIMER 2 A2 A 21 22 COMP AUX NC RELAY 2 DELAY TIMER 1 12 HOUR L 1 H DEFROST DEFROST LIGHT STAT Com BREAKS H ON TEMP FALLING OJ SMART CLOCK 2 FEED TERMINALS a NO
38. NOTE MCB CONTACTS MCB ALARM CONTACTS MCB AUX CONTACTS SHOWN WITH CIRCUIT BREAKER MANUALLY SWITCHED TO THE ON CONDITION WATER FLOW SWITCH CONTACTS SHOWN WITH WATER FLOW AT MAXIMUM RATE MCB SETTINGS ALL OTHER CONTACTS SHOWN IN DE ENERGISED STATE BUT WITH REFRIGERATION CIRCUIT FULLY CHARGED FAN FAN WHERE CONTACTS ARE MARKED N O OR N C ON CIRCUIT DIAGRAM ABOVE CONDITIONS APPLY CONTRO 1 2 1 2 25 368A 368A 27A 270 FAN 1 COMP 1 CONTACTOR CIRCUIT BREAKER FAN 1 AUX BLK TRIP OFF BREAK CONTACT CONTACTOR 63 64 6 NIC 5 6 NIC 3 1 4 DELAY TIMER 4 30 SECS COMP 2 CONTACTOR iwi T 1 16 NIC AUX BLK 12 NC 2 0 63 64 i 18 N O Kr 2 CIRCUIT BREAKER FAN2 RELAY R3 8 COM CONTACTOR COMP 1 AUX BLK CONTACTOR AUX BLK 53 54 0 53 54 N O 2 5 1 CIRCUIT BREAKER COMP 1 BREAKCONTACT CONTACTOR NC 5m 6 N O L3 ANC 4 2 COMP 2 NIC 1 2 0 L1 RELAY R4 x 83 52
39. NTACTS SHOWN WITH CIRCUIT BREAKER MANUALLY SWITCHED TO THE ON CONDITION WATER FLOW SWITCH CONTACTS SHOWN WITH WATER FLOW AT MAXIMUM RATE ALL OTHER CONTACTS SHOWN IN DE ENERGISED STATE BUT WITH 21 COMP AUX NC 63 64 LIQUID LINE SHUT OFF VALVE REFRIGERATION CIRCUIT FULLY CHARGED WHERE CONTACTS ARE MARKED N O OR N C ON CIRCUIT DIAGRAM ABOVE CONDITIONS APPLY COMP AUX NO 541 RELAY R2 DELAY R1 NIC k DEFROST 69 LIGHT DEFROST STAT BREAKS TO H ON TEMP FALLING 5 DIG STAT 1 STAGE SMART CLOCK FEED TERMINALS MAKES 6 TO 4 ON TEMP FALLING LIRUN 4072 1 COM SWITCH STANDBY N C 3 N O 4 STANDBY FLOW OK LIGHT 9 1 o RELAY R1 WATER FLOW SWITCH SOFT START THERMAL O LOAD amp FAULT LIGHT IF FITTED 1H 4 COM NIC COM INTERLOCI TERMINAL STARTER OR EXTERNAL FLOW SWITCH LP SWITCH BREAKS TO H ON PRESSURE FALLING HP SWITCH NO L BREAKS TO L ON PRESSURE RISING TK Ix FAN THERMAL CUT OUT COMPRESSOR MOTOR PROTECTOR N C 96 FANMCBAUXBLK ALARM TRIP BREAK CONTACT 96 COMPRESSOR MCB AUX BLK ALARM 95 TRIP BREAK CONT
40. Owner Installation Manual for PROPAC 30 45 70 90 140 M MY AIR WATER HEAT PUMPS SD566252 ISSUE 28 18 03 11 CONTENTS AIRIWATER HEAT PUMPS Eas Eo 2 THE HEAT PUMP CYCLE E cvs se El ce Eus LE ERN Eu Lass ERE EET RE 3 INSTALLATION ETT 4 4 2 FLOW EMIL 4 6 4 DETERMINING WATER FLOW 2555 d eR a l n ra idR 8 5 0 ELECTROLYTIC CORROSION IN SWIMMING POOLS 9 5 1 ELECTRICAL MACHINE WIRING AND 10 ELECTRICAL CIRCUIT DIAGRAMS 2 0 13 REGULAR PLANNED MAINTENANCE 24 CONTROLS AND INDICATION LAMPS 25 THERMOSTAT IERI II 25 HEAT PUMP MALFUNCTION 27 DATA SHEETS inicia dit eii E RV D 30 INSTALLATION DRAWINGS 34 WINTERISATION PROCEDURE Conn nae eb Ero era aa ck e emi naa Coa E cene ER E 43 START UP PROCEDURE AFTER 43 WARRANTY CONDITIONS e
41. R COMPRESSOR 1 MCB 54 NIC 2 THERMAL TK FAULT 54000 CUTOUT TRIP OFF BREAK 5 FAN1THERMAL CUT OUT 2 MCB AUX 96 NIC BLK ALARM 95 TRIP BREAK CONTACT FAN 1 MCB AUX ALARM DELAY TIMER 1 TRIP BREAK CONTACT 12 HOUR 16 NIC T8 NTO A RELAY R1 E 2 NIC 11 CONTROL CIRCUIT PHASE BREAKER ROTATION MAINS LIGHT TRIP OFF BREAK CONTACT RELAY 2 13 12 L1 t NEUTRAL page 17 ELECTRICAL CIRCUIT DIAGRAM PROPAC140BM THREE PHASE 400V 3 N 50Hz MCB SETTINGS CONTROL COMPRESSORS 1 amp 2 FANS1 amp 2 2 5A 36 8A 27 SEEFIG 1 WHERE CONTACTS ARE MARKED OR ON CIRCUIT DIAGRAM DEFROST 1 ABOVE CONDITIONS APPLY 69 ALL OTHER CONTACTS SHOWN IN DE ENERGISED STATE BUT WITH SEE FIC ets REFRIGERATION CIRCUIT FULLY CHARGED 1 517 Mrs WATER FLOW SWITCH CONTACTS SHOWN WITH WATER FLOW AT 3 MAXIMUM RATE RELAY R5 6 9 MCB CONTACTS MCB
42. XIAL AXIAL 2 x AXIAL 2 x AXIAL Sound Pressure Level 3m dBA 62 64 68 73 71 DIMENSION DATA Width unpacked PPT mm 1555 1665 1810 2095 2240 Width unpacked PP mm 1555 2210 Depth unpacked mm 790 1060 1190 1190 1650 Height unpacked mm 1080 1310 1310 1330 1340 Width export packed mm 1745 1845 1990 2295 2440 Depth export packed mm 900 1170 1300 1310 1770 Height export packed mm 1250 1480 1480 1500 1505 NOTES 1 Weight and Dimensions Nett 2 Allow 500mm clearance to service panels 3 Minimum air temperature 7 C 4 Water to have correct balance pH 7 2 7 8 Free Chlorine 1 0 2 0 ppm Domestic 3 0 6 0 Commercial 5 Calorex reserve the right to change or modify models without prior notice 6 R407c Global Warming Potential GWP 1700 page 31 AIR TO WATER HEAT PUMPS FOR SWIMMING POOL AND HOT WATER APPLICATIONS 400 3N 50Hz UNITS BMY PROPAC PROPAC PROPAC PROPAC PROPAC model 30 45 70 90 140 UNITS DUTY Air On 20 C 65 RH HEATING Output To Water 26 C kW 32 40 62 80 124 Electrical Input kW 7 8 9 75 14 4 19 5 29 Air On 10 C 8096 RH Output To Water 26 C kW 25 5 32 50 64 100 Electrical Input kW 7 3 8 12 5 16 25 Air On 0 C 9996 RH Output To Water 26 C kW 19 2 23 8 36 50 1 71 9 Electrical Input kW 5 98 7 67 10 96 16 17 21 93 ELECTRICAL DATA Electrical Supply 3 Phase V ph Hz 400V 3N 50Hz Minimum Supply Capacity 3 Phase amps 20 25 42 50
43. e heat pump must be maintained to the service requirements on page 21 IF IN ANY DOUBT PLEASE ASK Note The Reply Paid Warranty Registration Card must be returned to ensure that the correct warranty is given If you do not find a Registration Card with your Heat Pump please contact the Calorex Service Department giving your name address and serial number of your heat pump A card will be sent to you for completion 9 Email service calorex com SS e sz Website http www calorex com 44 0 1621 857171 SS 44 0 1621 856611 3d 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 44 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 that the test is carried out For machines affected see datasheets Asample log sheet can be seen below Serial Number Plant Name Location of Plant Plant Operator Refrigerant Type Refr gerant Quantity installed kg Plant manufacturer Calorex Heat Pumps Limited Year of installation Refrigerant Additions Q d 2 5 3 5 m 2 Date Engineer Amount Added k Reason for addition Company Name
44. ee ae E 44 MACHINE RECORD LOG Ea las cinia t El ua coda Fe E FX ERR EA Fa e E a E a RR 45 page 1 AIR WATER HEAT PUMPS MODELS PROPAC 30 45 70 90 140 The Calorex Propac range of air water heat pumps for swimming pool applications consist of 5 models Heat pumps on this manual are designed for heating pool water and spas within the range 7 C to 40 C with high water flow rate The titanium water heat exchanger is suitable for fresh and salt water pools Units with the suffix M are suitable for outdoor pools operating in ambient temperatures above 10 C units with the suffix MY are suitable for outdoor pools operating in ambients 15 C to 40 C The units are fully packaged and should be sited outside in a well ventilated area Other features include integral safety devices to protect the heat pump from internal and external faults Indicator lamps indicate operating mode An adjustable thermostat controls water temperature Also a 6 minute timer is incorporated A 12 hour delay timer is incorporated into all machines which after a power interruption or from initial start will prevent the machine compressor s from starting for a 12 hour period This feature is to protect the compressors from liquid pumping which can cause internal compressor damage IMPORTANT NOTE Calorex Heat Pumps Limited is an 509001 2000 certified company Calorex heat pumps are CE
45. he cooling cycle this the compressor process is reversed This pressure is released by passing the liquid through Coefficient of Performance The efficiency of a Heat Pump is usually called its Coefficient of Performance 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 Naturally this ratio will vary according to the temperature of the water and the ambient air page 3 INSTALLATION 1 SITING NOTE These units are not recommended for plant room 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 d Provide a firm level base capable of supporting operational weight of unit spread load on timber floor e Ensure water cannot collect under unit recommend units are installed on plinth 100mm above finished floor level and also to aid condensate drainage f Allow adequate clearance to service panels o
46. inimum Free Area m Inlet Discharge PROPAC 30 0 59 0 25 PROPAC 45 0 98 0 42 PROPAC 70 1 19 0 52 PROPAC 90 1 731 0 84 PROPAC 140 2 138 1 04 page 5 3 PLUMBING The Calorex Pool 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 should be connected between the filter and the other heater See Figures 3 amp 4 a Calorex Heat Pumps have water inlet outlet connections as follows MODEL Water in out MODEL Water in out connection size connection size PROPAC PPT30 1 BSPM PROPAC 45 1 BSPM PROPAC PPT45 2 BSPM PROPAC 70 1 BSPM PROPAC PPT70 2 BSPM PROPAC 90 17 BSPM PROPAC PPT90 3 BSPM PROPAC 140 2 BSPM 140 3 BSPM b Suitable breakable couplings should be installed local to heat pump If heat pump installed at lower level than pool water then isolation valves should fitted d Drain valve or plug should be fitted to lower pipe to facilitate drain down in winter period e The condensation from the evaporator fins drains away through holes in the base of the unit If desired an optional factory fitted driptray with 172 sink fitting can be fitted to allow the condensate to drain 172 domestic waste piping In this case it is necessary to ensure that the Calorex Heat Pump is placed on a level plinth so that the condensate can run away with adequate fall to waste ie 12 per foot minimum A U trap should also be inc
47. n unit recommend 500mm minimum see installation drawings g All Calorex heat pumps are by design as quiet as is practical however due consideration should be given to siting in order to fully exploit this feature i e ensure that the inlet and outlet grilles face away from occupied premises h Ensure loose debris such as leaves grass cuttings etc will not block air inlet filters or grilles i Consider protection from extreme weather conditions 2 AIR FLOW Due consideration must be given to air flow ie do not obstruct inlet or outlet and ensure discharge air cannot recirculate to inlet see figures 1 and 2 FIGURE 1 FIGURE 2 TYPICAL OUTSIDE INSTALLATION TYPICAL INSIDE OR PLANTROOM INSTALLATION NOT RECOMMENDED CANOPY OR OBSTRUCTION OO CLOSE 4 7 ADEQUATE 7 DUCTING 4 1 PROPAC M X c Z 30 45 70 PROPAC 90 140 page 4 1 Required Free Areas to provide air flow to and from heat pumps when installed an enclosed area or where required to pass through a wall etc Free area is the available area through which air can pass through a grille or louvres Note 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 TABLE 1 MODEL M
48. o service panels 3 Minimum air temperature 7 C 4 Water to have correct balance pH 7 2 7 8 Free Chlorine 1 0 2 0 ppm Domestic 3 0 6 0 Commercial 5 Calorex reserve the right to change or modify models without prior notice 6 R407c Global Warming Potential GWP 1700 page 32 AIR WATER HEAT PUMPS FOR SWIMMING POOL AND HOT WATER APPLICATIONS DUTY Air On 20 C 65 RH Output To Water 26 C Electrical Input Air On 10 C 80 RH Output To Water 26 C Electrical Input Air On 0 C 99 RH Output To Water 26 C Electrical Input ELECTRICAL DATA Electrical Supply 3 Phase Minimum Supply Capacity 3 Phase Recommended Supply Fuse 3 Phase Max Starting Current STD LRA Max Starting Current S Start LRA AIR DATA Nominal Air Flow Fan Resistance Fan Resistance WATER DATA PPT PROPAC Water Flow 10 Pressure Drop Water Water Connections Condensate Water Connections Optional Factory Fit ALL WATER DATA PP PROPAC Water Flow 10 Pressure Drop Water Water Connections GENERAL DATA Hermetic System Gas Charge R407c PPT Gas Charge R407c PP Compressor Type Fan Type Sound Pressure Level 3m DIMENSION DATA Width unpacked PPT Width unpacked PP Depth unpacked Height unpacked Width export packed Depth export packed Height export packed NOTES 1 Weight and Dimensions Nett 220V 3 ov 3 EMY
49. orporated into the pipework f 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 back pressure If everything is then working normally the water circulating system is ready to use CORRECT DRAINAGE FOR CONDENSATE U TRAP SUPPLIED BY CONTRACTOR g Water circuit to and from unit to be capable of maintaining within specified limits the rate of flow required by heat pump see data sheet h All pipework must be adequately supported with allowance for expansion contraction especially with plastic pipework i It is recommended that when installing water system the last connections to be made in the system should be the breakable couplings to avoid any stresses on to the unit connections page 6 IMPORTANT 1 All pool purifying devices and chemical injection systems to be fitted down stream of heat pumps unless installation is as per filter dosing see figure 3 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 pH 7 2 7 8 Total Alkalinity 80 120 ppm as CaCO Total dissolved solids 1000 Max ppm Saline Water Cupro Nickel Condenser 8 000 Max ppm Chlorine free
50. out prior notice 6 6 R407c Global Warming Potential GWP 1700 page 30 SWIMMING POOL AND HOT WATER APPLICATIONS AIR TO WATER HEAT PUMPS FOR 220V 3 60Hz UNITS EM PROPAC PROPAC PROPAC PROPAC PROPAC model 30 45 70 90 140 UNITS DUTY Air On 20 C 6596 RH HEATING Output To Water 26 C kW 32 40 62 80 124 Electrical Input kW 7 8 9 75 14 4 19 5 29 ELECTRICAL DATA Electrical Supply 3 Phase V ph Hz 220V 3 Minimum Supply Capacity 3 Phase amps 42 1 84 2 Recommended Supply Fuse 3 Phase amps 59 118 Max Starting Current STD LRA amps 205 205 Max Starting Current S Start LRA amps 26 26 AIR DATA Nominal Air Flow m hr 6300 12000 14000 24000 28000 Fan External Resistance mm WG 0 0 0 0 0 Fan External Resistance F mm WG N A 4 5 6 4 5 6 WATER DATA PPT PROPACS Water Flow 10 L min 123 246 369 492 738 Pressure Drop Water m hd 4 2 4 8 1 4 5 6 7 4 Water Connections inches 172 2 2 3 BSPM 3 Condensate Water Connections Optional Factory Fit ALL inches 1 BSPM 1 BSPM X2 1 PP PROPACS Water Flow 10 L min 66 133 266 Pressure Drop Water m hd 2 1 4 5 5 3 Water Connections inches 1 BSPM 12 BSPM 2 BSPM GENERAL DATA Hermetic System Gas Charge 407 PPT kg 5 5 14 18 14 X2 20 5 X2 Gas Charge R407c PP kg 5 5 14 X2 30 X2 Compressor Type SCROLL SCROLL SCROLL 2xSCROLL 2x SCROLL Fan Type AXIAL A
51. prevents damage to the refrigeration circuit WARRANTY CONDITIONS The following conditions apply to the Warranty given by Calorex Heat Pumps Ltd No claims will be accepted if 1 The heat pump is incorrectly sized for the application 2 The heat pump is installed in any way that is not in accordance with the current procedures as defined by Calorex Heat Pumps Ltd 3 heat pump has been worked upon is adjusted by anyone other than a person authorised to do so by Calorex Heat Pumps Ltd 4 The air flow to and from the machine is outside the specified limits 5 The water flow through the machine is outside the specified limits 6 The water pH level and or chemical balance is outside the following limits 72 78 80 120 150 250 1000 Total Alkalinity ppm Total Hardness as ppm Total Dissolved Solids ppm Acidi Maximum Salt Content with Titanium Condenser 35 000 Maximum Salt Content with Cupro Nickel Condenser ppm 8 000 Free Chlorine Range 1 2 Domestic Free Chlorine Range ppm 3 6 Commercial Superchlorination max 30ppm for 24 hrs ppm ppm ppm H Bromine 2 5 Baquacil ppm 25 50 Ozone ppm 0 9 Max Maximum Copper Content 1 Aquamatic lonic Purifier ppm 2 T The heat pump has suffered frost damage 8 electrical supply is insufficient or in anyway incorrect 9 Th
52. r year page 24 CONTROLS AND INDICATION LAMPS THERMOSTAT Adjustable single stage digital thermostat controls and maintains heating level Press and release P key to display required temperature to alter required temperature press up or down symbols After 5 seconds display reverts to actual water temperature NOT USED INCREASE SET POINT DECREASE SET POINT ACCESS SET POINT STANDBY SWITCH J 7 966 PP30 45 70 4 MAINSIN FAULT DEFROST WATER FLOW OK page 25 NOT USED INCREASE SET POINT DECREASE SET POINT ACCESS SET POINT 0 1 B eel STANDBY SWITCH 2765 6 69 E PP90 140 MAINS GENERAL FAULT FAULT FRIDGE CIRCUIT 1 FAULT FRIDGE CIRCUIT 2 DEFROST v WATER FLOW page 26 immediately to your installer to Calorex HEAT PUMP MALFUNCTION WARNING Isolate machine electrically before entering machine or 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 If in doubt or if advice required contact Calorex Service Department Telephone
53. sure Drop Water m hd 4 2 4 8 1 4 5 6 7 4 Water Connections inches 1 BSPM 2 2 3 BSPM 3 BSPM Condensate Water Connections Optional Factory Fit ALL inches 1 BSPM 17 BSPM X2 PP PROPACS Water Flow 1090 L min 66 66 266 Pressure Drop Water m hd 2 1 4 2 5 3 Water Connections inches 1 BSPM 1 BSPM 2 BSPM GENERAL DATA Hermetic System Gas Charge R407c PPT kg 5 5 14 18 14 X2 20 5 X2 Gas Charge R407c PP kg 5 5 14 30 X2 Compressor Type SCROLL SCROLL SCROLL 2xSCROLL 2x SCROLL Fan Type AXIAL AXIAL AXIAL 2 x AXIAL 2 x AXIAL Sound Pressure Level 3m dB A 62 64 68 73 71 DIMENSION DATA Width unpacked PPT mm 1555 1665 1810 2095 2240 Width unpacked PP mm 1555 1665 2210 Depth unpacked mm 790 1060 1190 1190 1650 Height unpacked mm 1080 1310 1310 1330 1340 Weight unpacked PPT PROPACS kg 219 314 407 Weight unpacked PP PROPACS kg 872 Width export packed mm 1745 1845 1990 2295 2440 Depth export packed mm 900 1170 1300 1310 1770 Height export packed mm 1250 1480 1480 1500 1505 Weight export packed PPT PROPAC kg 528 1028 Weight export packed PP PROPACS kg NOTES 1 Weight and Dimensions Nett 2 Allow 500mm clearance to service panels 3 Minimum air temperature 7 C 4 Water to have correct balance pH 7 2 7 8 Free Chlorine 1 0 2 0 ppm Domestic 3 0 6 0 Commercial 5 Calorex reserve the right to change or modify models with
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