Installation Manual PPT8/12/16/22L/LY
Contents
1. 72 7 8 80 120 150 250 1000 35 000 1 2 Domestic 3 6 Commercial 30ppm for 24 hrs o 3 Total Dissolved Solids Maximum Salt Content Free Chlorine Range Free Chlorine Range Superchlorination Bromine Baquacil Ozone Maximum Copper Content Aquamatic lonic Purifier o D 3 5 5 N 2 25 50 0 9 Max ke 3 _ 2 Max ke 3 7 The heat pump has suffered frost damage 8 The electrical supply is insufficient or in anyway incorrect Page 37 Calorex Heat Pumps Ltd The Causeway Maldon Essex CM9 4XD UK Tel 44 0 1621 857 171 nstallation Manual PPT8 12 16 22L LY 14 0 Contacting Calorex Email service calorex com Website http www calorex com Tel 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 38 Calorex Heat Pumps Ltd The Causeway Maldon Essex CM9 4XD UK Tel 44 0 1621 857 1712. PPT22BLY STANDARD HEAT PUMP Installation Manual PPT8 12 16 22L LY 7 0 Regular planned maintenance Operations to be carried out during a regular planned maintenance visit are as follows Clean the evaporators This action may be required more frequently than regular servicing Check operation of 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 driptrays and internal drain lines for blockages and clear Check operation of controls and calibrate if necessary Check operation of interlocks in use Final check of overall operation of unit Indicate on Service report any faults found or causes for concern Recommended servicing frequencies Light to medium use visit per year Heavy use two visits per year Page 23 Calorex Heat Pumps Ltd The Causeway Maldon Essex CM9 4XD UK Tel 44 0 1621 857 171 nstallation Manual PPT8 12 16 22L LY 8 0 Controls and indication lamps CONSOLE MAINS RED Electrical supply on FAULT AMBER Internal or external fault condition DEFROST WHITE Defrost Mode WATER FLOW GREEN Water flowing at adequate rate Page 24 Calorex Heat Pumps Ltd The Causeway Maldon Essex CM9 4XD UK Tel 44 0 1621 857 171 Installation Manual PPT8 12 16 22L LY 8 1 Digital Thermo
3. 2400 3 502 TOTAL POWER CONSUMED AMBIENT 10 C WATER 24 C 2 3 2 6 41 AMBIENT 20 C WATER 24 i 2 5 3 3 4 3 MIN SUPPLY CAPACITY Max F L A 1 ph N 174 19 0 MIN SUPPLY CAPACITY Max F L A 3 ph N 6 2 8 0 MAX SUPPLY FUSE 1 ph N 25 0 30 0 MAX SUPPLY FUSE 3 ph N 10 0 15 0 WATER FLOWS ETC POOL WATER FLOW RATE mn 115 123 POOL WATER PRESSURE DROP Rated Flow m hd 2 5 2 5 3 5 MAX WORKING PRESSURE POOL WATER bar 3 5 3 5 3 5 POOL WATER CONNECTIONS inches 1 1 2 BSPM CONDENSATE DRAIN CONNECTIONS inches 3 4 DOMESTIC WASTE COMPRESSOR NOMINAL POWER CONSUMED 1 8 L R A 1 ph N 66 R L A 1 ph N SOFT START AMPS 1 ph N 18 L R A 3 ph N 32 R L A 3 ph N 4 SOFT START AMPS 3 ph N 14 MAIN FAN AIR FLOW Anemometer air on grille Wet evaporator MAX EXTERNAL STATIC PRESSURE F L A 1 ph N GENERAL DATA HERMETIC SYSTEM GAS CHARGE R407c PHYSICAL DIMENSIONS WIDTH DEPTH HEIGHT Unpacked WEIGHT Unpacked 93 FOR ACCURATE APPLICATION SIZING CONSULT CALOREX HEAT PUMPS LTD NOTES 1 Weight and dimensions nett 2 Performance design limitations Ambient 7 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
4. INTERLOCK TERMINALS MODEL FUSE PROPAC T 8ALY 3A PROPAC T 12ALY 3A CONTROL FUSE MAINS LIGHT e NEUTRAL Calorex Heat Pumps Ltd The Causeway Maldon Essex CM9 4XD UK Tel 44 0 1621 857 171 nstallation Manual PPT8 12 16 22L LY 16 22 ALY SINGLE PHASE 230V 1N 50Hz PROPAC16 22 ALY SINGLE PHASE 230V 1 50Hz VOLT FREE POOL PUMP 2J RUN 3 NO f i Tore i NIC NO NIO 3 6 14 i POOL PUMP DELAY TIMER i SYNCHRONISATION T2 3 MINS NIC wo 16 18 w wo wc No gt DELAYTIMER 36 o 20 4 T3 1 Hr RUN CAPACITOI i CONTACTOR i FUSE RATINGS No MODEL FUSE ms PPT16ALY 3A Qu RELAY T PPT22ALY 3A CAPACITOR IF FITTED OVERLOAD SETTING MODEL REVERSING VALVE DELAY TIMER PETIBAEE 6 NS PPT22ALY e DEFROST LIGHT WANDA A2 SENSOR m Ts 1 poo STANDARD HEAT THERMOSTAT FLOW LIGHT PUMP WATER FLOW SWITCH A SOFT START THERMAL OVERLOAD wo w AND FAULT LIGHT IF FITTED f 95 COMPRESSOR TL Nc ALARM 4 96 iL L P SWITCH silos BREAKS ON PRESSURE 0 FALLING A H P SW
5. STANDARD HEAT PUMP P oret POOL WATER FLOW LIGHT m 6 WATER FLOW SWITCH SOFT START THERMAL OVERLOAD i NC N O amp FAULT LIGHT IF FITTED LP BREAKS ON SWITCH N PRESSURE FALLING 1c HP BREAKS ON SWITCH PRESSURE RISING TERMINAL INTERLOCK TERMINALS MAINS LIGHT NEUTRAL Page 17 Calorex Heat Pumps Ltd The Causeway Maldon Essex CM9 4XD UK Tel 44 0 1621 857 171 nstallation Manual PPT8 12 16 22L LY 16 22 AL SINGLE PHASE 230V 1N 50Hz VOLT FREE POOL PUMP RUN 22 IER i i i NC iNo 3 6 1 DELAY i TIMER 2 A 3 MINS POOL PUMP SYNCHRONISATION 1 18 NO NC NC NO 58 1 TIMER T3 1 Hr RUN CAP CONTACTOR O LOAD i FUSE RATINGS MODEL FUSE PPT16AL 3A PPT22AL 3A START IF FITTED OVERLOAD SETTING MODEL PPT16AL DELAY TIMER 1 PPT22AL 6 MINS i FAN CAP DEFROST SAT Mel DEFROST LIGHT SENSOR WATER FLOW LIGHT STANDARD 7 5 HEAT PUMP WATER FLOW SWITCH SOFT START THERMAL OVERLOAD Wc mo amp FAULT 104 LIGHT IF FITT
6. AND LIFT OFF Qy M MAINS IN s BOTH ENDS SST FIGURE 5 22 2 NIN Oo ZSO m SINGLE PHASE 230V 1N 50Hz SWITCH SOFT START KIT L 10 SENSOR 18 VOLT FREE POOL PUMP RUN SENSOR 20 WATER PRESSURE THREE PHASE 400V 3N 50Hz D WATER PRESSURE SWITCH SOFT START KIT L 10 SENSOR 18 SENSOR 20 VOLT FREE POOL PUMP RUN Page 14 Calorex Heat Pumps Ltd The Causeway Maldon Essex CM9 4XD UK Tel 44 0 1621 857 171 Installation Manual PPT8 12 16 22L LY 5 0 Optional Features 5 1 Pool Pump Synchronisation For installations where the filter pump which also priovides water to your 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 three minutes each hour so
7. for details of pressure switch position If the heat pump has lost it s gas a specialist refrigeration technician should investigate further Page 27 Calorex Heat Pumps Ltd The Causeway Maldon Essex CM9 4XD UK Tel 44 0 1621 857 171 nstallation Manual PPT8 12 16 22L LY Three phase units only Three phase units incorporate a phase rotation and voltage sensing relay If the unit will not start and the fault light is illuminated check that the neon lamp indicating correct connection situated within the phase rotation relay which is positioned within the electrics box is illuminated If this light is not illuminated change over two of the incoming heat pumps supply phases If the heat pump tries to start then stops very quickly it is possible that the power supply to the heat pump is delivering inadequate voltage This will occur if the voltage drops below 380 volts This could be caused by either inadequately sized cable or general problems with the voltage supply on site Larger three phase heat pumps will also utilise thermal overloads that will trip in the event of single phasing These are located as part of the compressor contactor and can be reset by pressing the rectangular red button located at the base of this contactor See manual for exact position of contactor 2 Water leaks swimming pool heat pump produces condensed water that would normally be discharges into a drain Condensed water is fed to was
8. replace lid of heat pump and restore power to the heat pump SENSOR LEADS TO BE RUN SEPARATELY o ojoojo ojo 10114213 141546 9 o REMOTE STAT L 10 REMOTE STAT N O 14 REMOTE STAT COM 16 REMOTE STAT N 12 REMOTE STAT SENSOR 20 REMOTE STAT SENSOR 18 REMOVE LINKS AND WIRE TO TERMINAL SHOWN ILLUMINATED LAMP DENOTES HEATING To Change the temperature press and release the P key to display required temperature to alter required temperature press the up or down keys After 5 seconds the display reverts to actual water temperature Page 16 Calorex Heat Pumps Ltd The Causeway Maldon Essex CM9 4XD UK Tel 44 0 1621 857 171 Installation Manual PPT8 12 16 22L LY 6 0 Circuit Diagrams PPT8 12 AL SINGLE PHASE 230V 1N 50Hz VOLT FREE POOL PUMP 22 RUN 27 NO TIMER T2 i A 3 MINS POOL PUMP SYNCHRONISATION NO 16 18 FUSE RATINGS MODEL FUSE PPT8AL 3A RUN CAP PPT12AL 3A CONTACTOR SOFT START wo 2 FITTED i i 5 SIAL COMPRESSOR RELAY HARD START CAP IF FITTED DELAY TIMER T1 6 MINS DEFROST L STAT NO DEFROST d LIGHT SENSOR
9. 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 untl 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 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 Page 15 Calorex Heat Pumps Ltd The Causeway Maldon Essex CM9 4XD UK Tel 44 0 1621 857 171 nstallation Manual PPT8 12 16 22L LY 5 2 Remote Thermostat A remote thermostat kit is available which allows the user of the heat pump to control the setting of the heat pump away from the heat pump for example from inside the home Please note the thermostat is rated at IP40 and is not suitable for outdoor use NOT USED INCREASE SET POINT ACCESS SET POINT DECREASE SET POINT With the heat pump isolated electrically remove lid from heat pump and disconnect the links as shown Connect wires between heat pump and remote thermostat as shown in the diagram below See label inside thermostat cover for further information When correctly connected
10. there is adequate water flow through the heat pump by checking that there are no by pass or isolating valves incorrectly positioned and that the sand filter does not require backwashing Defrost light If the white defrost light is illuminated check that the evaporator coil is clean If dirty clean with a soft brush Greasy debris can be removed with amild chemical cleaner and pressure washer Also check that the heat pump is installed in a free space that will not allow exhausted cold air to re circulate back into the heat pump This can be checked by measuring the air temperature at the point where it enters the heat pump and comparing this to the actual ambient air temperature They should be the same If the temperature of the air entering the heat pump is lower recirculation is occurring This will cause premature defrosting and poor performance In air temperatures below 15 automatic defrosting may occur as part of the heat pumps normal operation Fault light This will illuminate if a The heat pump is wired with external controls across its interlock and these controls are open circuit These controls would normally be an external time clock or volt free terminals on the filter pump contactor and would be wired across the terminals shown as interlock on the incoming customer interface within the heat pump b The heat pump has lost its gas This can be checked by measuring continuity across the low pressure switch see manual
11. ATER IN OUT 172 BSPM PPT12 9552 ones WATER OUT WATER IN CONDENSATE o MAINS IN AIR OFF Page 32 Calorex Heat Pumps Ltd The Causeway Maldon Essex CM9 4XD UK Tel 44 0 1621 857 171 Installation Manual PPT8 12 16 22L LY CONDENSATE 34 DOMESTIC WASTE WATER IN OUT 172 BSPM PPT16 AIR OFF Page 33 Calorex Heat Pumps Ltd The Causeway Maldon Essex CM9 4XD UK Tel 44 0 1621 857 171 tion Manual nstalla PPT8 12 16 22L LY 696 6cc 6 31VSN3QNOO NI NI SNIVIA ALSVM 9Il1S3NOd 31LVSN3QNOO INdS8 1 LNO NI H3 LVM 350 34 Calorex Heat Pumps Ltd The Causeway Maldon Essex 9 4XD UK Tel 44 1621 857 171 0 Installation Manual PPT8 12 16 22L LY 12 0 Winterisation Procedure WARNING Isolate machine before removing covers The heat pump embodies electrical and rotational equipment it is recommended for your own safety t
12. Allow adequate clearance to service panels on unit recommend 500mm minimum f 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 g Ensure loose debris such as leaves grass cuttings etc will not block air inlet grilles h Consider protection from extreme weather conditions if installed externally i e lean to cover or building Page 6 Calorex Heat Pumps Ltd The Causeway Maldon Essex CM9 4XD UK Tel 44 0 1621 857 171 Installation Manual PPT8 12 16 22L LY 2 2 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 figure 1 POSSIBLE POSITIONS OF A CALOREX HEAT PUMP Suitable opening 4 gt 50cm PLANT SWIMMING POOL SPA __ TABLE 1 Required Free Areas to provide air flow to Minimum Free Area m and 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 0 264 0 173 Free areas is the available area through 0 308 0 173 which air can pass through a grille or louvres Note if multiple units are installed in enclosed area then the inlet free areas required
13. Causeway Maldon Essex CM9 4XD UK Tel 44 0 1621 857 171 Installation Manual PPT8 12 16 22L LY The Calorex Swimming pool heat pump provides thermodynamic heating by means of a vapour compression cycle similar to that employed ina conventional refrigerator in addition to acting as an active solar collector 1 2 Function 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 vaporises This preheated vapour now travels to 2 THE COMPRESSOR where itis compressed and upgraded to a much higher temperature The hot vapour now enters THE HEAT PUMP CYCLE COMPRESSOR POOL WATER OUT AMBIENT AIR HEAT EXCHANGER POOL WATER IN CONDENSED COOL LIQUID REFRIGERANT REFRIGERANT EXPANSION VALVE LOW PRESSURE SIDE HIGH PRESSURE SIDE 3 THE CONDENSER where it is surrounded by the pool water The heat is given up to the cooler 4 THE EXPANSION DEVICE and from there pool water and the now cooler refrigerant returns now at normal pressure it is returned to the to its former liquid state but still under high evaporator and the cycle starts again p
14. ED FRUG p 95 COMPRESSOR O gut O LOAD ALARM b LP BREAKS ON SWITCH PRESSURE FALLING A BREAKS ON PRESSURE RISING INTERLOCK TERMINALS CONTROL FUSE MAINS LIGHT NEUTRAL Page 18 Calorex Heat Pumps Ltd The Causeway Maldon Essex CM9 4XD UK Tel 44 0 1621 857 171 Installation Manual PPT8 12 16 22L LY PPT8 12 ALY SINGLE PHASE 230V 1N 50Hz VOLT FREE POOL PUMP RUN 3 NO 3 DELAY TIMER T2 POOL PUMP SYNCHRONISATION pF 16 18 A2 56 194 Q DELAY 25 1H N 9 8 j 1 2 1 6 EE RELAY HARD START CAPACITOR IF FITTED A OMPRESSOR REVERSING VALVE DEFROST LIGHT DELAY TIMER DEFROST STAT SENSOR STANDARD HEAT PUMP WATER FLOW LIGHT e WATER FLOW SWITCH THERMAL wo OVERLOAD amp FAULT LIGHT IF FITTED L P SWITCH BREAKS ON PRESSURE FALLING H P SWITCH BREAKS ON PRESSURE RISING TERMINAL BLOCK FUSE RATINGS
15. G TERMINAL INTERLOCK TERMINALS 8 N O 12 4 N O 0 MAINS LIGHT 2 N O L 11 COM Q L3 L2 11 CONTROL CIRCUIT PHASE ROTATION RELAY NEUTRAL BREAKER Page 21 Calorex Heat Pumps Ltd The Causeway Maldon Essex CM9 4XD UK Tel 44 0 1621 857 171 nstallation Manual PPT8 12 16 22L LY 8 12 16 22 BLY THREE PHASE 400V 3N 50Hz VOLT FREE POOL PUMP RUN 23 HNIC NO 1 1 NO 1216 18 NIC 3 6 1 4 TIMER 72 NIC NC NO 2286 2 5 1 42 TIMER ma COMPRESSOR REVERSING VALVE DEFROST LIGHT DEFROST CONTROL STAT SENSOR 6 WATER FLOW LIGHT SOFT START THERMAL OVERLOAD amp FAULT LIGHT IF FITTED LP BREAKS ON SWITCH PRESSURE FALLING HP BREAKS ON SWITCH PRESSURE RISING INTERLOCK TERMINALS com 4 WATER FLOW No SWITCH e NO 1 4 12 2 N O MAINS LIGHT 11 COM L3 L2 L1 CON BREAKER Calorex Heat Pumps Ltd The Causeway Maldon Essex CM9 4XD UK Tel 44 0 1621 857 171 ION RELAY NEUTRAL Page 22 POOL PUMP SYNCHRONISATION FUSE RATINGS MODEL PPT8BLY PPT12BLY PPT16BLY
16. ITCH aie BREAKS ON PRESSURE qo RISING INTERLOCK TERMINAL TERMINALS Pa BLOCK e FAULT LAMP CONTROL FUSE MAINS LAMP NEUTRAL Page 20 Calorex Heat Pumps Ltd The Causeway Maldon Essex CM9 4XD UK Tel 44 0 1621 857 171 Installation Manual PPT8 12 16 22L LY 8 12 16 22 BL THREE PHASE 400V 3N 50Hz VOLT FREE POOL PUMP RUN 22 23 i NO IK sS NE PB i i NIC i i i 3 6 114 iB i R4 R3 f DELAY pA TIMER T2 i A 3 MINS POOL PUMP SYNCHRONISATION NO 46 18 i 2250 1 45 TIMER T3 S es we CONTACTOR A wo 6 Wi paa 4 V1 COMPRESSOR A Mr U1 MCB SETTING MODEL FUSE 2 PPT8BLY 2 5A DELAY PPT12BLY 2 5A TIMER PPT16BLY 2 5A 6 MINS l PPT22BLY 2 5A DEFROST STAT amp LIGHT SENSOR STANDARD HEAT PUMP WATER FLOW LIGHT WATER FLOW N O SWITCH SOFT START A THERMAL 1 OVERLOAD NC NO amp FAULT 1 B LIGHT IF FITTED Bi LP 4 69 LIGHT BREAKS ON SWITCH N c amp PRESSURE FALLING H HP NIC db BREAKS ON SWITCH PRESSURE RISIN
17. Installation Manual PPT8 12 16 22L LY OWNER INSTALLATION MANUAL FOR PPT8 12 16 22L LY SD617650 Iss X 08 12 09 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 Page 1 Calorex Heat Pumps Ltd The Causeway Maldon Essex CM9 4XD UK Tel 44 0 1621 857 171 nstallation Manual PPT8 12 16 22L LY Congratulations You are now an owner of a Calorex Heat pump Page 2 Calorex Heat Pumps Ltd The Causeway Maldon Essex CM9 4XD UK Tel 44 0 1621 857 171 Installation Manual PPT8 12 16 22L LY Contents 1 0 Introduction and Function 1 1 Introduction 1 2 Function 2 0 Installation 2 1 Siting 2 2 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 13 4 2 Location of Mains Input and External Interlock Terminals 5 0 Optional Features 5 1 Pool Pump Kit 5 2 Remote Thermostat 6 0 Circuit Diagrams 7 0 Regular planned maintenance 8 0 Controls and indication lamps 8 1 Digital Thermostat 9 0 Heat Pump Malfunction 10 0 Datasheets 11 0 Installation Drawings 12 0 Winterisation Procedure 12 1 Start up Procedure After Winterisation 13 0 Warranty Conditions 14 0 Contactin
18. JATVA al NHAL3M dalvaH xnv NON Page 10 1621 857 171 0 Tel 44 Essex CM9 4XD Maldon Calorex Heat Pumps Ltd The Causeway Installation Manual PPT8 12 16 22L LY 3 2 Determining Water Flow The heat pump is fitted with a water flow switch which inhibits the operation of the heat pump when the water flow is below 50001 Adjust the flow rate until the flow light green lamp is illuminated This lamp indicates that the water flow through the heat pump is adequate FLOW LIGHT POOL WATER OUT REMOVE BUNGS BEFORE INSTALLING HEAT PUMP POOL WATER IN T Q CONDENSATE DRAIN HEAP PUMP SIDE PPT8 12 FLOW RATE 115 litres per minute PPT 16 22 FLOW RATE Page 11 Calorex Heat Pumps Ltd The Causeway Maldon Essex CM9 4XD UK Tel 44 0 1621 857 171 nstallation Manual PPT8 12 16 22L LY 4 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 mate
19. PRESSURE FLA 1 ph N GENERAL DATA HERMETIC SYSTEM GAS CHARGE R407c PHYSICAL DIMENSIONS WIDTH Un packed DEPTH HEIGHT Un packed WEIGHT Un packed FOR ACCURATE SIZING CONSULT CALOREX HEAT PUMPS LTD NOTES 1 Weight and dimensions nett 2 Performance design limitations Ambient 15 C min 35 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 Pa 1 1 4 psi 1I min 0 22gall min Page 30 Calorex Heat Pumps Ltd The Causeway Maldon Essex CM9 4XD UK Tel 44 0 1621 857 171 Installation Manual PPT8 12 16 22L LY 11 0 Installation Drawings calore 8 E CONDENSATE 34 DOMESTIC WASTE WATER IN OUT 172 PPT8 m diee ATER OUT CCONDENSATE AIR OFF Page 31 Calorex Heat Pumps Ltd The Causeway Maldon Essex CM9 4XD UK Tel 44 0 1621 857 171 nstallation Manual PPT8 12 16 22L LY CONDENSATE DOMESTIC WASTE W
20. ata 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 Frequency 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 1596 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 Calorex Heat Pumps Ltd The Causeway Maldon Essex CM9 4XD UK Tel 44 0 1621 857 171 nstallation Manual PPT8 12 16 22L LY 4 2 Location of Mains Input and External Interlock Terminals REMOVE SCREWS FROM TOP I COVER
21. change or modify models without prior notice 6 R407c Global warming potential GWP 1700 1mm WG 9 8 Pa 1 1 4 psi 11 0 22gall min Page 29 Calorex Heat Pumps Ltd The Causeway Maldon Essex CM9 4XD UK Tel 44 0 1621 857 171 nstallation Manual PPT8 12 16 22L LY HEAT PUMPS FOR OUTDOOR POOLS REVERSE CYCL DEFROST ALY BLY MODEL Units 8 12 HEAT TO POOL WATER AMBIENT 10 C WATER 24 C 7 2 ELECTRICAL ELECTRICAL SUPPLY 1 PHASE 230 1 50 ELECTRICAL SUPPLY 3 PHASE 400V 3N 50Hz TOTAL POWER CONSUMED AMBIENT 10 C WATER 24 C kWhr 1 8 2 3 3 1 AMBIENT 20 C WATER 24 C kWhr 2 0 2 5 3 3 MIN SUPPLY CAPACITY Max F L A 1 ph N amps 174 19 0 MIN SUPPLY CAPACITY Max F L A 3 ph N amps 6 0 6 2 8 0 MAX SUPPLY FUSE 1 ph N amps 25 0 30 0 MAX SUPPLY FUSE 3 ph N amps 10 0 15 0 WATER FLOWS ETC POOL WATER FLOW RATE litres min 115 123 POOL WATER PRESSURE DROP Rated Flow metres hd 25 2 5 25 MAX WORKING PRESSURE POOL bar 3 5 3 5 3 5 POOL WATER CONNECTIONS inches 11 2 BSPM _ CONDENSATE DRAIN CONNECTIONS inches 3 4 DOMESTIC WASTE COMPRESSOR NOMINAL POWER CONSUMED 1 8 2 14 LRA 1 ph N 66 63 RLA 1 ph N 14 SOFT START AMPS 1 ph N 18 18 LRA 3ph N 32 30 RLA 3 ph N 4 SOFT START AMPS 3 ph N 14 14 MAIN FAN AIR FLOW Anemometer air on grille Wet evaporator MAX EXTERNAL STATIC
22. 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 Calorex Heat Pumps Ltd The Causeway Maldon Essex CM9 4XD UK Tel 44 0 1621 857 171 nstallation Manual PPT8 12 16 22L LY 3 0 Plumbin a Calorex Heat Pumps have water inlet outlet connections as follows All models have 172 BSP parallel male threads 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 b 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 figure 4 Suitable breakable couplings should be installed local to the heat pump d If the heat pump is installed at a lower level than the pool then isolation valves should be fitted e Adrain valve or plug should be fitted to the lower pipe to facilitate drain down in the winter period f Connections on all models are by BSP parallel male threaded fittings These should be hand tightened only otherwise damage may result to the threads of the plastic fittings g The condensate drain at the base of the unit collects condensation from the evaporator fins This should run away to waste via domestic waste pi
23. g Calorex Page 3 Calorex Heat Pumps Ltd The Causeway Maldon Essex CM9 4XD UK Tel 44 0 1621 857 171 nstallation Manual PPT8 12 16 22L LY 1 0 Introduction and Function 1 1 Introduction The Calorex Propac range of air water heat pumps are 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 are suitable for outdoor pools operating in ambient temperatures above 10 C Reverse cycle defrost models 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 PP 16 22 heat pumps are fitted with scroll compressors Both types of compressor are known for quiet running 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 Also a 6 minute cycle time delay is incorporated IMPORTANT NOTE Calorex Heat Pumps Limited is an 509001 2000 certified company All Calorex heat pumps are CE approved Page 4 Calorex Heat Pumps Ltd The
24. hat 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 a drain valve if fitted b disconnecting pipework to and from heat pump 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 located outside protect from weather by covering with VENTILATED cover Do not use plastic sheet as condensation could occur within unit N B If this procedure is not adopted and frost or corrosion damage results then the warranty will become invalid Page 35 Calorex Heat Pumps Ltd The Causeway Maldon Essex CM9 4XD Tel 44 0 1621 857 171 nstallation Manual PPT8 12 16 22L LY 12 1 Start up Procedure After Winterisation Replace covers if not fitted Remove fr
25. installation is as per filter dosing see figure 4 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 72 78 Total Alkalinity 80 120 ppm as CaCO3 Total Hardness 150 250 ppm as Total dissolved solids Max 1000 ppm Saline Water Max 35 000 ppm Chlorine free Cl Range 1 0 2 0 ppm Domestic Chlorine free 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 3kg cm 50 psi Page 9 Calorex Heat Pumps Ltd The Causeway Maldon Essex CM9 4XD UK Tel 44 0 1621 857 171 Manual tion nstalla PPT8 12 16 22L LY 3 1 Recommended Plumbing Schematic e gt 3A VA AVM 338H L 3A VA NON Le SNIIdnoo a3 18vxvasua 3NTVA NOLLV IOSI BN A33 NOILOANNOO ONIHSN14 SNISIS3 LNIM gt MOd lWOdauvds ALSVM OL S31VM ALVSNAGNOO Q3 LLId YASILINVS 41 191110 diNNd LV3H 3AO8V WWOOL LHSISH WAWINIA GALVYOdHOONI 38 OL d Pref OO NS L38 ILNV oH dWNd LV3H X3HO lVvO NMOGQ NIV3G ALSVM OL ai 3OIA3d WOINSHO H3JSILLINVS SNISIS3 LNIM SLSVM OL
26. it control fuse on single phase machine Check MCB on three phase machine Check water and air flows are not restricted Check thermal cut out on Soft Start if fitted and that air flow is not restricted Check unit control fuse on single phase machine Check MCB on three phase machine FAN ON COMPRESSOR OFF PERATES Page 26 Unit on defrost heating mode check that air temperature is not below 7 C 15 C for Y models Check evaporator is clean INTERMITTENTLY Check water and air flows are not restricted and that electrical supply is adequate Check airflow to machine Check that linked in external equipment is not the cause of the fault Calorex Heat Pumps Ltd The Causeway Maldon Essex CM9 4XD UK Tel 44 0 1621 857 171 Installation Manual PPT8 12 16 22L LY Outdoor swimming pool heat pump troubleshooting checklist 1 Warning Lights Check the status of the warning lights For correct operation the red mains light should be illuminated green water flow light should be illuminated except under cold ambient conditions the white defrost light should be extinguished and the amber fault light should be extinguished Mains Light If the mains light is off there is no power to the unit This light is wired directly across the incoming electrical supply and therefore only illuminates when the incoming supply is healthy Water flow light If the green water flow light is not illuminated check that
27. ont grille Using a soft brush clean finned surfaces of heat pump Replace panel Remove plastic covers on water connections and reconnect water piping or close drain valve 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 Replace fuses to heat pump circuit Switch on heat pump Check control thermostat is set to required pool temperature Check pool water daily to ensure it is at correct pH and has correct chemical balance See Section 3 Plumbing Page 36 Calorex Heat Pumps Ltd The Causeway Maldon Essex CM9 4XD UK Tel 44 0 1621 857 171 Installation Manual PPT8 12 16 22L LY 13 0 Warranty Conditions The following exclusions apply to the Warranty given by Calorex Heat Pumps Ltd No claims will be ac cepted if 1 The heat pump is incorrectly sized for the application 2 The heat pump is installed any way that is not in accordance with the current procedures as defined by Calorex Heat Pumps Ltd 3 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 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 Acidity pH Total Alkalinity as CaCO Total Hardness as
28. ping 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 77 per foot minimum and must incorporate a u trap as to not overflow the edges of the drip tray inside the heat pump See figure 3 THIS TYPE OF INSTALLATION INCORRECT DRAINAGE SHOULD BE AVOIDED CORRECT DRAINAGE FOR CONDENSATE FOR CONDENSATE 7 8 Calorex Heat Pumps Ltd The Causeway Maldon Essex CM9 4XD UK Tel 44 0 1621 857 171 Installation Manual PPT8 12 16 22L LY h 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 for use i 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 10 j All pipework must be adequately supported with allowance expansion contraction especially with plastic pipework k 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 unless
29. ressure from the compressor 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 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 ratio will vary according to the temperature of the water and the ambient air Page 5 Calorex Heat Pumps The Causeway Maldon Essex CM9 4XD UK Tel 44 0 1621 857 171 nstallation Manual PPT8 12 16 22L LY 2 0 Installation 2 1 Siting a Ensure heat pump on site is as ordered i e model electrical supply and factory fitted options b Inspectunitfor 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 c Provide a firm level base capable of supporting operational weight of unit spread load if mounted on timber floor d 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 e
30. rial to degrade A swimming pool with its associated equipment can create this ef fect 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 cre ate 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 hand rails It is highly recommended that bonding be retrofitted to existing pools which may not be protected by this system Page 12 Calorex Heat Pumps Ltd The Causeway Maldon Essex CM9 4XD UK Tel 44 0 1621 857 171 Installation Manual PPT8 12 16 22L LY 4 1 Electrical Machine Wiring and Supply SEE FIGURES 5 6 7 AND 8 FOR PREFERRED METHOD 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 line with EMC2004 108 EC Protected supply to incorporate fuses or motor type circuit breakers Type C to specified rating see D
31. stat An adjustabe single stage digital thermostat controls and maintains the water temperature Press and release the P key to display required temperature to alter required temperature press the up or down keys After 5 seconds the display reverts to actual water temperature Increase Set Point Decrease Set Point Access Set Point Page 25 Calorex Heat Pumps Ltd The Causeway Maldon Essex CM9 4XD UK Tel 44 0 1621 857 171 nstallation Manual PPT8 12 16 22L LY 9 0 Heat Pump Malfunction WARNING Isolate heat pump electrically before entering heat pump 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 immediately to an installer or Calorex If in doubt or if advice is required contact Calorex Service Department Telephone 44 0 1621 857171 or 856611 User Check List MAINS FAULT DEFROST WATER FLOW MAINS FAULT DEFROST WATER FLOW MAINS FAULT DEFROST WATER FLOW MAINS FAULT DEFROST WATER FLOW MAINS FAULT DEFROST WATER FLOW MAINS FAULT DEFROST WATER FLOW UNIT DOES N ACTION OT OPERATE Check mains supply external fuses isolator etc Water flow inadequate or faulty flow switch First check water flow then Check un
32. te via a condensate connection on the machine that is connected to a waste pipe If either the pipe or connector becomes blocked with dirt condensate will overflow from the heat pumps internal drip tray and leak from the base of the heat pump rather than falling away to waste In this case the pipe and connector should be cleaned Inthe event that the heat pump appears to have a water leak but this water is not overflowing from the drip tray carefully inspect all the joints within the heat pumps heat exchanger assembly and repair as necessary General rule of thumb guide checking 1 After switching on the heat pump will take approx six minutes to start This is due to inbuilt time delays within the heat pump that protect the unit from cycling 2 Air leaving the heat pump should be 8 to 10 degrees colder than its entering temperature 3 Water leaving the heat pump should be no more than 3 degrees warmer than its entering temperature 4 On warm days a steady trickle of condensate water should discharge from the condensate drain Page 28 Calorex Heat Pumps Ltd The Causeway Maldon Essex CM9 4XD UK Tel 44 0 1621 857 171 Installation Manual PPT8 12 16 22L LY 10 0 Datasheets HEAT PUMPS FOR OUTDOOR POOLS SUMMER SEASON AL BL MODEL Units PPT8 HEAT TO POOL WATER AMBIENT 10 C WATER 24 C AMBIENT 20 C WATER 24 C ELECTRICITY ELECTRICAL SUPPLY 1 PHASE 230V 1N 50Hz ELECTRICAL SUPPLY 3 PHASE 7
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