Installation Manual PPT8/12/16/22L/LY
Contents
1. CONDENSATE 272 DOMESTIC WASTE WATER IN OUT 172 BSPM PPT8 i 42000 WATER OUT WATER IN CONDENSATE 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 24 DOMESTIC WASTE WATER IN OUT 172 BSPM PPT12 859 opem WATER OUT WATER IN CONDENSATE o MAINS IN AIR OFF Page 33 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 77 DOMESTIC WASTE WATER IN OUT 172 BSPM PPT16 AIR OFF Page 34 Calorex Heat Pumps Ltd The Causeway Maldon Essex CM9 4XD UK Tel 44 0 1621 857 171 Installation Manual PPT8 12 16 22L LY WATER IN OUT 172 BSPM CONDENSATE DOMESTIC WASTE PPT22 CONDENSATE WATER IN MAI2. BREAKS ON PRESSURE RISING TERMINAL INTERLOCK TERMINALS 1 MAINS LIGHT f COM e P PHASE ROTATION L3 L2 L1 CIRCUIT RELAY NEUTRAL BREAKER 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 0 Regular planned Operations to be carried out during a regular planned maintenance visit are maintenance as follows 1 Clean the evaporators This action may be required more frequently than regular servicing 2 Check operation of fans and compressors 3 Check capacitor tolerances where fitted 4 Check condition of all heat exchangers evaporators 5 Check refrigeration system parameters 6 Check operation of control valves 7 Check for water leaks 8 Check driptrays and internal drain lines for blockages and clear 9 Check operation of controls and calibrate if necessary 10 Check operation of interlocks in use 11 Final check of overall operation of unit 12 Indicate on Service report any faults found or causes for concern 13 Recommended servicing frequencies Light to medium use one visit per year Heavy use two visits per year Page 25 Calorex Heat Pumps Ltd The Causeway Maldon Essex CM9 4XD UK Tel 44 0 1621 857 171 Installation Manual PPT8 12 16 22L LY 9 0 Heat Pump WARNING Isolate heat pump electrically before entering he
3. CONTROL FUSE MAINS LIGHT NEUTRAL Page 19 Calorex Heat Pumps Ltd The Causeway Maldon Essex CM9 4XD UK Tel 44 0 1621 857 171 Installation Manual PPT8 12 16 22L LY PPT16 22 AL SINGLE PHASE 230V 1N 50Hz POOL PUMP RUN 22 23 NIC N O 1 4 wc wo wc o R3 DELAY TIMER T2 A 3MINS NIC N O 16 18 N O Ni iNO N C FUSE RATINGS TIMER T3 MODEL 1 Hr Al PPT16AL PPT22AL OVERLOAD SETTING MODEL PPT16AL PPT22AL RUN CAP CONTACTOR O LOAD wo 2 1 NO 3 No RELAY HARI START CAP IF FITTED DELAY TIMER T1 6MINS i FAN CAP l DEFROST STAT NS DEFROST k LIGHT SENSOR WATER FLOW LIGHT e WATER FLOW SWITCH SOFT START THERMAL OVERLOAD xi we NO amp FAULT E 1 LIGHT IF FITTED COMPRESSOR r4 O LOAD ALARM LP BREAKS ON SWITCH PRESSURE FALLING BREAKS ON PRESSURE RISING INTERLOCK TERMINALS CONTROL FUSE MAINS LIGHT e 1 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 PPT8 12 ALY SINGLE PHASE 230V 1N 50Hz VOLT FREE POOL
4. Protected supply to incorporate fuses or motor type circuit breakers Type C to specified rating see Data Sheet H R C fuses are recommended An isolator which disconnects all poles must be fitted within 2m and in sight of machine T All units must be correctly earthed grounded An earth leakage trip of the Current operating type 30mA is recommended to be fitted to all pool electrics INCONSISTENT ELECTRICAL SUPPLY The following limits of operation must not be exceeded if Calorex machines are to be guaranteed either in performance or warranty terms Minimum Maximum Voltage single phase 207V 253V Voltage three phase 360V 440V 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 15 less than the nominal voltage 415V for 3N 50Hz The lamp on the phase rotation relay situated in the electric box is illuminated when the phases are correctly connected and the voltage is sufficient IMPORTANT The user should be made aware that THE WHOLE installation should be isolated when working on ANY PART Page 13 Calorex Heat Pumps Ltd The Causeway Maldon Essex CM9 4XD UK Tel 44 0 1621 857 171 Installation Manual PPT8 12 16
5. REMOTE STAT COM 16 REMOTE STAT SENSOR 20 REMOTE STAT SENSOR 18 V REMOVE LINKS AND WIRE TO TERMINAL SHOWN x 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 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 AL SINGLE PHASE 230V 1N 50Hz 7 0 Circuit Diagrams POOL PUMP RUN 22 23 NIO NIC N O NIC N O 3 6 1 R3 DELAY TIMER T2 A 3MIN 18 wo 4 re I FUSE RATINGS MODEL FUSE TIMER T3 1 Hr A1 PPT12AL 3A PPT8AL 3A RUN CAP CONTACTOR 5 gt H i M i RELAY HARD START CAP IF FITTED T1 6 MINS DEFROST STAT c DEFROST LIGHT L SENSOR WATER FLOW LIGHT A WATER FLOW SWITCH SOFT START THERMAL H i i NIC N O 1 4 OVERLOAD amp FAULT r LIGHT i IF FITTED oL LP NIO BREAKS ON SWITCH c PRESSURE FALLING GOAT LIGHT sReASON SWITCH o PRESSURE RISING INTERLOCK TERMINALS
6. perature c Water leaving the heat pump will typically be no more than 3 C warmer than its entering temperature d On warm days a steady trickle of condensate water should discharge from the condensate drain Page 29 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 J 400V 3NI 50Hz TOTAL POWER CONSUMED AMBIENT 10 C WATER 24 C 23 26 4 1 AMBIENT 20 C WATER 24 C 25 28 43 MIN SUPPLY CAPACITY Max F L A 1 ph N 17 0 21 0 MIN SUPPLY CAPACITY Max F L A 3 ph N 6 4 8 0 RECOMMENDED SUPPLY FUSE 1 ph N 25 0 30 0 RECOMMENDED SUPPLY FUSE 3 ph N 10 0 15 0 WATER FLOWS ETC POOL WATER FLOW RATE L min 115 123 POOL WATER PRESSURE DROP Rated Flow m hd 2 5 2 5 3 5 MAX WORKING PRESSURE POOL WATER bar 2 5 2 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 FL
7. _ COMPRESSOR hh mo Ut T1 A1 DELAY TIMER FAN CAP 6 MINS DEFROST STAT amp LIGHT SENSOR A ws gI POOL oS STAT WATER FLOW LIGHT com 4 d md I 69 e AM WATER FLOW wo SWITCH e SOFT START THERMAL OVERLOAD NIC NO amp FAULT LANE B LIGHT IF FITTED put L E P ucxr ereacson SWITCH N c PRESSURE FALLING A H HP NIC BREAKSON SWITCH o PRESSURE RISING INTERLOCK i TERMINALS 6 N O 4 N O 1 io MAINS LIGHT 2 N O Q L3 L2 L1 CON IRCUIT BREAKER NEUTRAL Page 23 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 16 22 BLY THREE PHASE 400V 3N 50Hz VOLT FREE POOL PUMP RUN 22 23 NO s wc o wc o R3 DELAY TIMER T2 A 3MINS N O NC o N C NO 4 FUSE RATINGS TIMER T3 MODEL 1 Hr PPT8BLY At PPT12BLY PPT16BLY PPT22BLY CONTACTOR i W1 T3 COMPRESSOR SO i j V1 T2 oe i Lut wo sH REVERSING VALVE DEFROST CONTROL STAT DEFROST LIGHT FAN CAP SENSOR WATER FLOW LIGHT e WATER FLOW SWITCH SOFT START THERMAL i OVERLOAD NIC NO amp FAULT 1 4 LIGHT IF FITTED FAULT LP LIGHT BREAKS ON SWITCH PRESSURE FALLING
8. 1 Required Free Areas to provide air flow to and Minimum Free Area m from heat pumps when installed in an en Inlet Discharge closed 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 which 0 308 0 173 lair can pass through a grille or louvres IMPORTANT If multiple units are installed in an enclosed area then the inlet free areas required for each unit can be added together to form one inlet aperture BUT discharge from each unit must be kept separate and must not be incorporated into one common duct system Page 7 Calorex Heat Pumps Ltd The Causeway Maldon Essex CM9 4XD UK Tel 44 0 1621 857 171 Installation Manual PPT8 12 16 22L LY 3 0 Plumbing a Calorex Heat Pumps have water inlet outlet connections as follows All models have 172 BSP parallel male threads b The heat pump is supplied with bungs fitted in the water connection fittings These need to be removed before the heat pump is installed See section 3 2 c The Calorex Heat Pump must be connected after the filter in the return pipe to the pool If an existing heater is being retained then the Calorex Heat Pump should be connected between the filter and the other heater See section 3 1 d Suitable breakable couplings should be installed local to the heat pump e If the heat pump is installed at a lower level than the pool then isolation valves should be
9. 22L LY REMOVE SCREWS FROM TOP 4 2 Location of Mains COVER AND BIBT ORF Input and External Interlock Terminals Bee MAINS IN eo p 00 000 00000000 ran 10111213 418 414 32d212223 SINGLE PHASE 230V 1N 50Hz opoloboopoloboooob Ci 2 CABLE ENTRY REMOTE STAT POINT L REMOTE INTERLOCK SOFT START INTERLOCK SENSOR 18 SENSOR 20 VOLT FREE POOL PUMP RUN cq e OO mui THREE PHASE 400V 3N 50Hz 121514184 dtd2d2 12223 O OO Hill mE 25 fd CABLE ENTRY REMOTE STAT POINT Page 14 Calorex Heat Pumps Ltd The Causeway Maldon Essex CM9 4XD UK Tel 44 0 1621 857 171 REMOTE INTERLOCK SOFT START INTERLOCK SENSOR 18 SENSOR 20 VOLT FREE POOL PUMP RUN Installation Manual PPT8 12 16 22L LY 4 3 Pool Pump For installations where the filter pump which also priovides water to your Synchronisation heat pump is controlled by a time clock supplied by the installer your Calorex heat pump can overridde pump off periods set on the time clock so that the filter pump will run if your swimming pool requires heating By doing so your fil
10. 5 0 Controls and indication lamps 5 1 Digital Thermostat 6 0 Optional Features 6 1 Remote Thermostat 7 0 Circuit Diagrams 8 0 Regular Planned Maintenance 9 0 Heat Pump Malfunction 9 1 User Check List 9 2 Outdoor Swimming Pool Heat Pump Checklist 10 0 Datasheets 11 0 Installation Drawings 12 0 Winterisation Procedure 12 1 Start up Procedure After Winterisation 13 0 Warranty Conditions 14 0 Contacting Calorex Page 3 Calorex Heat Pumps Ltd The Causeway Maldon Essex CM9 4XD UK Tel 44 0 1621 857 171 Installation Manual PPT8 12 16 22L LY 1 0 Introduction The Calorex Propac range of air to water heat pumps is designed for swimming pool heating and consists of 4 models Heat pumps in this manual are designed to heat pool water and spas within the range of 10 C to 40 C Standard units 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 PPT16 22 heat pumps are fitted with scroll compressors Both types of compressor are known for quiet running A6 minute compressor start delay timer is incorporated for compressor protection With these features the heat pump is desig
11. N 10 0 15 0 WATER FLOWS ETC POOL WATER FLOW RATE L min 115 123 POOL WATER PRESSURE DROP Rated Flow m hd 2 5 3 5 MAX WORKING PRESSURE POOL WATER bar 2 5 3 5 POOL WATER CONNECTIONS inches 1 1 2 BSPM CONDENSATE DRAIN CONNECTIONS inches 3 4 DOMESTIC WASTE COMPRESSOR NOMINAL POWER CONSUMED LRA 1 ph N RLA 1 ph N SOFT START AMPS 1 ph N LRA 3ph N RLA 3 ph N SOFT START AMPS 3 ph N MAIN FAN AIR FLOW Anemometer air on grille Dry evaporator FLA 1 ph N GENERAL DATA HERMETIC SYSTEM GAS CHARGE R407c PHYSICAL DIMENSIONS WIDTH Unpacked 1049 DEPTH Unpacked 593 HEIGHT Unpacked 720 WEIGHT Unpacked 102 FOR ACCURATE APPLICATION SIZING CONSULT CALOREXHEAT 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 1mhd 1 4 psi 1l min 0 22gall min Page 31 Calorex Heat Pumps Ltd The Causeway Maldon Essex CM9 4XD UK Tel 44 0 1621 857 171 Installation Manual PPT8 12 16 22L LY calorex Pro Pac 8 4
12. PUMP RUN 29 24 NIO N C JNO iC N O DELAY TIMER T2 wo FUSE RATINGS 18 EE MODEL TIMER T3 PPT 8ALY 1 Hr E PPT 12ALY RUN CAP CONTACTOR NO f 5 RELAY HARD START CAP IF FITTED REVERSING VALVE oe Q DEFROST LIGHT DEFROST CONTROL STAT SENSOR WATER FLOW LIGHT A WATER FLOW SWITCH SOFT START THERMAL OVERLOAD NC NO amp FAULT 1 4 LIGHT ort LIGHT IF FITTED LP BREAKS ON SWITCH PRESSURE FALLING HP BREAKS ON SWITCH PRESSURE RISING TERMINAL INTERLOCK TERMINALS CONTROL FUSE MAINS LIGHT 1 NEUTRAL Page 21 Calorex Heat Pumps Ltd The Causeway Maldon Essex CM9 4XD UK Tel 44 0 1621 857 171 Installation Manual PPT8 12 16 22L LY PPT16 22 ALY SINGLE PHASE 230V 1N 50Hz VOLT FREE POOL PUMP 22 RUN 23 w o 4 ic oo Ni 6 DELAY TIMER T2 A 3 MINS FUSE RATINGS w o 18 o N O N C N O N C N O MODEL FUSE 4 PPT16ALY 3A TIMER T3 1 Hr A1 PPT22ALY 3A OVERLOAD SETTING MODEL PPT16ALY PPT22ALY RUN CAP CONT
13. located outside protect from weather by covering with VENTILATED cover Do not use plastic sheet as condensation could occur within unit IMPORTANT If this procedure is not adopted and frost or corrosion damage results then the warranty will become invalid Page 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 12 1 Startup Procedure 1 Replace covers if not fitted After Winterisation 2 Remove front grille Using a soft brush clean finned surfaces of heat pump Replace panel 3 Remove plastic covers on water connections and reconnect water piping or close drain valve 4 Start up water circulating pump and leave running for at least 1 4 hour to establish flow and enable an air in piping to escape 5 Replace fuses to heat pump circuit 6 Switch on heat pump 7 Check control thermostat is set to required pool temperature 8 Check pool water daily to ensure it is at correct pH and has correct chemical balance See Section 3 Plumbing Page 37 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 The following exclusions apply to the Warranty given by Calorex Heat Pumps Conditions Ltd No claims will be accepted if The heat pump is incorrectly sized for the application The heat pump is installed in any way that is not in a
14. send a recorded delivery letter to transport company giving details Protect unit if installation is delayed 2 1 Siting a Provide a firm level base capable of supporting operational weight of unit spread load if mounted on timber floor b Ensure water cannot collect under unit it is recommend that units are installed on plinths 100mm above finished floor level This also aids condensate drainage c Allow adequate clearance to service panels on unit recommend 500mm minimum d All Calorex heat pumps are by design as quiet as is practical however due consideration should be given to siting the heat pump in order to minimise the noise coming from the machine for example by positioning the machine so that the inlet outlets are parallel to occupied premises e Ensure loose debris such as leaves grass cuttings etc will not block air inlet grilles f Consider protection from extreme weather conditions if installed externally i e lean to cover or building Page 6 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 below POSSIBLE POSITIONS OF A CALOREX HEAT PUMP uitable opening _ Suitable opening gt 50cm X3HOT1vo PLANT ROOM CALOREX SWIMMING POOL SPA 2 TABLE
15. ACTOR O LOAD 4 R P OMPRESSOR EI H RELAY HARD START CAP IF FITTED A REVERSING VALVE DEFROST CONTROL STAT DEFROST LIGHT FAN CAP SENSOR WATER FLOW LIGHT re WATER FLOW SWITCH SOFT START THERMAL OVERLOAD i nic Wo amp FAULT 1 4 LIGHT IF FITTED A COMPRESSORS L O LOAD ALARM LP BREAKS ON SWITCH PRESSURE FALLING HP BREAKS ON SWITCH PRESSURE RISING TERMINAL BLOCK INTERLOCK TERMINALS CONTROL FUSE MAINS LIGHT e NEUTRAL Page 22 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 16 22 BL THREE PHASE 400V 3N 50Hz VOLT FREE POOL PUMP 22 RUN 29 N C N O p M A4 1 4 B wc o e wo d B R4 R3 DELAY o A TIMER T2 com A 3 MINS NC NO A 16 18 A2 B MCB SETTING TIMER T3 SS 1 Hr R2 MODEL FUSE 15 Al can n PPT8BLY 2 5A PPT12BLY 2 5A PPT16BLY 2 5A PPT22BLY 2 5A CONTACTOR SEN n W1 T3 wo MT i Vi T2
16. 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 pressure 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 Ltd The Causeway Maldon Essex CM9 4XD UK Tel 44 0 1621 857 171 Installation Manual PPT8 12 16 22L LY 2 0 Installation a Ensure heat pump on site is as ordered i e model electrical supply and factory fitted options b Inspect unit for damage in particular inspect the evaporator finned side to ensure that itis undamaged Minor indentations in the fins do not affect performance If severely damaged endorse delivery note in presence of the driver and
17. Installation Manual PPT8 12 16 22L LY OWNER INSTALLATION MANUAL FOR PPT8 12 16 22L LY SD617650 Iss B 12 03 10 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 Installation Manual PPT8 12 16 22L LY Thank you for choosing Calorex Your Calorex heat pump has been specially designed for pool heating using high quality components that are carefully chosen to provide maximum efficiency and reliability Please read this manual carefully as it provides useful operation and maintenance information that will maximise the benefits your Calorex heat pump can offer SS SS WELLE Mi WIE WITHIN A iff ji 777 p lil 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 1 1 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 4 2 Location of Mains Input and External Interlock Terminals 4 3 Pool Pump Synchronisation
18. LV3H X3HO lVvO NMOGQ NIVG 31SVM OL Qaa Ll4 sl 30143A SNISOGQ VOIIW3HO HO H3SILINVS SNISIS3 LNIA HO4d 31S8VM OL INVA aalri al NHOL3M dalvaH xnv NON Page 10 Maldon UK Tel 44 Essex CM9 4XD Calorex Heat Pumps Ltd The Causeway Installation Manual PPT8 12 16 22L LY 3 2 Determining The heat pump is fitted with a water flow switch which inhibits the operation Water Flow of the heat pump when the water flow is below 5000l h 83 33l min 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 4 O POOL WATER OUT REMOVE BUNGS BEFORE INSTALLING HEAT PUMP POOL WATER IN 1 o CONDENSATE DRAIN s RR HEAP PUMP SIDE PPT8 12 FLOW RATE 115 litres per minute PPT16 22 FLOW RATE 123 litres per minute Page 11 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 0 Electrolytic Corrosion Electrolytic corrosion will occur when dissimilar metals that are in contact in Swimming Pools with each other create a potential difference between themselves Sometimes separated by a conductive substance known as an electrolyte the dissimilar metals will create a small voltage potential difference that allows the ions of one material to pass to the other Just
19. NS IN WATER OUT 150 230 LO o N N N AIR OFF Page 35 Calorex Heat Pumps Ltd The Causeway Maldon Essex CM9 4XD UK Tel 44 0 1621 857 171 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 that a competent person carries out the following procedure ALL MODELS Objective To provide frost protection To eliminate corrosion problems To inhibit electrical components 1 Switch off electric supply to heat pump 2 Remove external fuses and keep in safe place away from heat pump to prevent accidental operation of heat pump 3 Ensure water circulation pump is switched off 4 Drain water from heat pump by 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
20. OW Anemometer air on grille Dry evaporator F L A 1 ph N GENERAL DATA HERMETIC SYSTEM GAS CHARGE R407c PHYSICAL DIMENSIONS WIDTH Unpacked DEPTH Unpacked HEIGHT Unpacked WEIGHT Unpacked 93 FOR ACCURATE APPLICATION SIZING CONSULT CALOREXHEAT 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 change or modify models without prior notice 6 R407c Global warming potential GWP 1700 1mm WG 9 8 Pa 1mhd 1 4 psi 1l 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 HEAT PUMPS FOR OUTDOOR POOLS REVERSE CYCLE DEFROST ALY BLY MODEL Units PPT8Y PPT12Y PPT16Y PPT22Y HEAT TO POOL WATER AMBIENT 10 C WATER 24 C ELECTRICAL ELECTRICAL SUPPLY 1 PHASE 230V 1N 50Hz ELECTRICAL SUPPLY 3 PHASE 400V 3N 50Hz TOTAL POWER CONSUMED AMBIENT 10 C WATER 24 C 23 26 AMBIENT 20 C WATER 24 C 25 28 MIN SUPPLY CAPACITY Max F L A 1 ph N 17 0 21 0 MIN SUPPLY CAPACITY Max F L A 3 ph N 6 4 8 0 RECOMMENDED SUPPLY FUSE 1 ph N 25 0 30 0 RECOMMENDED SUPPLY FUSE 3 ph
21. Thermostat An adjustable 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 Not used CEPR WI 6 Ce Increase Set Point P v Decrease Set Point Access Set Point Page 17 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 Optional Features 6 1 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 replace lid of heat pump and restore power to the heat pump SENSOR LEADS TO BE RUN SEPARATELY ojo olojolojo o o o o 1011121314151617 819 20 o ojele o e REMOTE STAT L 10 REMOTE STAT N 12 REMOTE STAT N O 14
22. at pump or Malfunction removing panels The user check list should be carried out before initiating a service call Do not attempt to interfere with any internal control settings as these have been factory calibrated and sealed Any sign of abnormal operation such as water dripping should be reported immediately to an installer or Calorex If in doubt or if advice is required contact Calorex Service Department 9 1 User Check List ACTION UNIT DOES NOT OPERATE OFF OFF OFF OFF ON Page 26 Check mains supply external fuses isolator etc Water flow inadequate or faulty flow switch First check water flow then Check unit 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 CONTINUED OVERLEAF Calorex Heat Pumps Ltd The Causeway Maldon Essex CM9 4XD UK Tel 44 0 1621 857 171 Installation Manual PPT8 12 16 22L LY 9 2 Outdoor swimming pool heat pump checklist Mains light Water flow light ACTION FAN ON COMPRESSOR OFF 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 sup
23. ccordance with the current procedures as defined by Calorex Heat Pumps Ltd The heat pump has been worked upon or is adjusted by anyone other than a person authorised to do so by Calorex Heat Pumps Ltd The air flow to and from the machine is outside the specified limits The water flow through the machine is outside the specified limits The water pH level and or chemical balance is outside the following limits Acidity pH Total Alkalinity as CaCO3 80 120 Total Hardness as CaCO 150 250 ppm Total Dissolved Solids Maximum Salt Content 35000 Max Bromine 2 5 7 The heat pump has suffered frost damage 8 The electrical supply is insufficient or in any way incorrect Page 38 Calorex Heat Pumps Ltd The Causeway Maldon Essex CM9 4XD UK Tel 44 0 1621 857 171 Installation Manual PPT8 12 16 22L LY 14 0 Contacting Email service calorex com Calorex 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 39 Calorex Heat Pumps Ltd The Causeway Maldon Essex CM9 4XD UK Tel 44 0 1621 857 171
24. ese devices are an external time clock or volt free terminals on the filter pump contactor which would be wired across the terminals labelled as interlock on the terminal block in the heat pump electric box These devices can intentionally prevent the heat pump from operating C Check thermostat set point is higher than the measured water tempera ture If the thermostat is not satisfied with the temperature the red LED above the label Out on the digital display will be illuminated d If the compressor attempts to start then stops very quickly it is possi ble that the power supply to the heat pump is delivering inadequate voltage This will occur if the voltage drops below 380 volts It could be caused by either an inadequately sized cable or general problems with the voltage supply on site 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 Three phase units only e Three phase units incorporate a phase rotation and voltage sensing relay If the RED mains light is illuminated but the digital display is off check the red lamp situated on the phase rotation relay located within the electrics box indicating correct phase connection is illuminated If this light is not illumi nated isolate and change over two of the incoming heat pump supply phases Note that this relay also protects against low voltage and loss of one or more phases so c
25. fitted f Adrain valve or plug should be fitted to the lower pipe to facilitate drain down in the winter period g Connections on all models are by BSP parallel male threaded fittings These should be hand tightened only otherwise damage may result to the threads of the plastic fittings h The condensate drain at the base of the unit collects condensation from the evaporator fins This should run away to waste via 74 domestic waste piping It is therefore necessary to ensure that the Calorex Heat Pump is placed on a level plinth so that the condensate water can run away with adequate fall to waste i e 72 per foot minimum and must incorporate a u trap as to not overflow the edges of the drip tray inside the heat pump See below THIS TYPE OF INSTALLATION INCORRECT DRAINAGE SHOULD BE AVOIDED CORRECT DRAINAGE FOR CONDENSATE FOR CONDENSATE Page 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 i When the pipework installation is complete the pool pump should be switched on and the system tested for leaks Also check the filter gauge to see that there is not an excessive increase in back pressure If everything is then working normally the water circulating system is ready for use j Water circuit to and from the unit is to be capable of maintaining within specified limits the rate of flow required by the heat pump See secti
26. heck this possibility if the heat pump has previ ously operated normally Larger three phase heat pumps 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 Water leaks A swimming pool heat pump condenses water vapour from the atmosphere during operation This condensate is collected in a drip tray at the base of the heat pump from where it drains through a condensate connection on the side of the machine which should be connected to a waste pipe to be discharge into a drain If either the pipe or connector becomes blocked with dirt condensate will overflow from the internal 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 In the 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 pump heat exchanger assembly for pool water leaks and repair as necessary General rule of thumb a After switching on the heat pump will take approx six minutes to start This is check list due to inbuilt time delays within the heat pump that protect the compressor from short cycling b Air leaving the heat pump should be 8 to 10 C colder than its entering tem
27. 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 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 All electrical work to be carried out in accordance with I E E standards latest Wiring and Supply issue or local codes of practice as applicable The machine should be installed in line with EMC2004 108 EC
28. ned to have a long trouble free life All units have integral safety devices to protect the heat pump from internal and external faults Indicator lamps indicate operating mode An adjustable digital thermostat controls water temperature Calorex Heat Pumps Limited is an I80O9001 2000 certified company All Calorex heat pumps are CE approved Page 4 Calorex Heat Pumps Ltd The Causeway Maldon Essex CM9 4XD UK Tel 44 0 1621 857 171 Installation Manual PPT8 12 16 22L LY 1 1 Function The Calorex Swimming pool heat pump provides thermodynamic heating by means of a vapour compression cycle similar to that employed in a conventional refrigerator in addition to acting as an active solar collector 1 THE EVAPORATOR oollects 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 COOL GAS OOoOoOooO POOL WATER OUT AMBIENT AIR HEAT EXCHANGER POOL WATER IN D CONDENSED
29. on 10 k All pipework must be adequately supported with allowance expansion contraction especially with plastic pipework 1 Itis recommended that when installing water systems the last connections to be made in the system should be breakable connections to avoid any stresses on the unit connections IMPORTANT 1 All Pool Purifying Devices and Chemical Injection Systems to be fitted down stream of the heat pump see section 3 1 unless installation is as per filter dosing This includes the practice of dosing chemicals direct into skimmer basket which results in concentrated corrosive liquids passing over vulnerable metal components 2 Water quality must be maintained as follows 2 5 Maximum Copper Content 1 Aquamatic lonic Purifier 3 Maximum pressure of water in heat pump circuit should not exceed 2 5bar for PPT8 12 35 psi and 3 5bar for PPT16 22 50 psi Page 9 Calorex Heat Pumps Ltd The Causeway Maldon Essex CM9 4XD UK Tel 44 0 1621 857 171 ANTWA AVM 338H L ne 3NTVA NYNLJ Y NON e SNIIdnoo 3 18vxvasua JAVA NOLLV3OSI MN A3 31SVM OL S31VM ALVSNAGNOO NOILOANNOO Q3 LLId YASILINVS 4l 1621 857 171 0 tion Manual Installa PPT8 12 16 22L LY 3 1 Recommended Plumbing Schematic ONIHSN14 SNISIS3 LNIM Od LHOd 38VdS i P fb PP a Ln P P E lHOd LAILNO dWAd LV3H 3AO8V WWOOL LHSISH WAWINIA T31VHOdHOONI 38 OL dOO NSPLE38 ILNV O dWNd
30. ost operation is observed or in air temperatures above 15 C a Check that the heat pump is installed such that exhausted cold air leaving the heat pump can not recirculate back into the heat pump air inlet 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 ofthe air entering the heat pump is lower recirculation is occurring This will cause premature defrosting and poor performance b Check that the airflow is not restricted by nearby obstructions that the air inlet is free from debris and that the evaporator coil is clean If dirty clean with a soft brush Greasy debris can be removed with a mild chemical cleaner and pressure washer Fault light a The heat pump has lost its refrigerant gas This can be checked by measuring continuity across the low pressure switch see manual for details of pressure switch position If the heat pump has lost its gas a specialist refrigeration technician should investigate further b When fitted with a soft start if the soft start cut out has activated Indication lights correct a If the RED mains light is illuminated but the digital display is off check but no operation the 3 amp control fuse single phase units or control circuit breaker three phase units in the electric box b Check external devices connected to the interlock Examples of th
31. ply is adequate Check airflow to machine Check that linked in external equipment is not the cause of the fault Check the status of the warning lights During normal operation The RED mains light should be illuminated The GREEN water flow light should be illuminated The AMBER fault light should not be illuminated The WHITE defrost light should only be illuminated in cold ambient conditions and when the heat pump is carrying out a defrost If the RED mains light is off power is not connected to the unit This light is wired between the incoming live and neutral cables and therefore illuminates when the incoming supply is healthy If the GREEN water flow light is not illuminated check for adequate water flow through the heat pump Ensure the flow rate from the water pump exceeds the minimum requirements Ensure that the pool water bypass valve if applicable is sufficiently closed to achieve minimum flow isolating valves to from the heat pump are fully open and that the sand filter does not require backwashing Page 27 Calorex Heat Pumps Ltd The Causeway Maldon Essex CM9 4XD UK Tel 44 0 1621 857 171 Installation Manual PPT8 12 16 22L LY Defrost light If the WHITE defrost light is illuminated the heat pump is carrying out an automatic defrost to remove ice formed on the evaporator In air temperatures below 15 C automatic defrosting may occur as part of the normal operation of the heat pump If abnormal defr
32. ter 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 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 Installation Manual PPT8 12 16 22L LY 5 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 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 5 1 Digital
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