Calorex 29 Series Guida rapida

Page 1

Owner Installation

Manual for

AW629, 829

AIR/WATER HEAT PUMPS

(SD546250 Issue a)

Page 2

Contents

AIR/WATER HEAT PUMPS FOR SWIMMING POOLS .................................................................................... 3

HOW THE HEAT PUMP WORKS .................................................................................................................... 4

INSTALLATION ............................................................................................................................................... 5

1.SITING ......................................................................................................................................................... 5

2.AIR FLOW .................................................................................................................................................... 6

3.PLUMBING ................................................................................................................................................... 7

RECOMMENDED PLUMBING SCHEMATIC .................................................................................................... 9

4. DETERMINING WATER FLOW ...................................................................................................................10

5.ELECTRICAL (MACHINE WIRING AND SUPPLY) ....................................................................................... 11

ELECTRICAL CIRCUIT DIAGRAM .................................................................................................................17

CONTROLS AND INDICATION LAMPS .........................................................................................................18

HEAT PUMP MALFUNCTION ......................................................................................................................... 19

DATA SHEET ..................................................................................................................................................20

INSTALLATION DRAWINGS ..........................................................................................................................21

WINTERISING PROCEDURE ......................................................................................................................... 23

START UP PROCEDURE AFTER WINTERISATION .......................................................................................24

WARRANTY CONDITIONS .............................................................................................................................25

CONTACTING CALOREX ...............................................................................................................................26

Page 3

AIR/WATER HEAT PUMPS FOR SWIMMING POOLS

MODELS AW629, 829

The Calorex ‘29’ range of air/water heat pumps is for swimming pool applications and consists

of 2 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 from 7°C to 40°C. The water heat exchanger is a full flow type, manufactured

from titanium, which is a highly corrosion resistant material. The heat pumps are suitable for

use in fresh water and salt water pools.The compressors fitted in the heat pumps are the

scroll type and 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.

Page 4

HOW THE HEAT PUMP WORKS

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 operating as an active

solar collector.

Cooled Air Exhaust Compressor

Expansion

Device

Outside Air Evaporator

(Heat Collector)

Pool Filter

Swimming

Pool

Condenser Heat Tranfered

to Pool Water

Pool Water

Pump

Pool Water

The EVAPORATOR collects heat from

the outside ambient air, pre-heated by the

sun. With Calorex, swimming pool heat

pumps high volumes of outside air are

drawn into the unit by the fan and 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 pre-heated vapour now travels to-

The COMPRESSOR

where it is compressed and

upgraded to a much higher

temperature.

The hot vapour now enters -

The CONDENSER where it is

surrounded by the pool water. The heat

is given up to the cooler pool water and

the now cooler refrigerant returns to its

former liquid state but still under high

pressure from the compressor.

This pressure is released by passing

the liquid through -

The EXPANSION DEVICE

and from there, now at low

pressure, it is returned to the

evaporator and the cycle starts

again.

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.

Naturally this ratio will vary according to the temperature of the water and the ambient air.

Page 5

INSTALLATION

1. SITING

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.

c Protect unit if installation is delayed.

d Provide a firm level base capable of supporting operational weight of unit; spread load if mounted on timber

floor.

e 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.

f Allow adequate clearance to service panels on unit; recommend 500mm minimum.

g 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.

h Ensure loose debris such as leaves, grass cuttings, etc will not block air inlet grilles.

i Consider protection from extreme weather conditions if installed externally, i.e. lean-to-cover or building.

Page 6

2. AIR FLOW

Due consideration must be given to air flow, i.e. do not obstruct inlet or outlet and ensure discharge air cannot

re-circulate to inlet. (See figure 1)

Suitable opening

> 50 cm

PLANT ROOM

WALL WALL

FIG 1 POSSIBLE POSITIONS OF A CALOREX 29 UNIT

SWIMMING POOL/SP

CALOREX 29

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.

Required Free Areas to provide air flow to

and from heat pumps when installed in an

enclosed area or where required to pass air

through a wall, etc.

Free area is the available area through which air

can pass through a grille or louvres.

MODEL

Inlet Discharge

AW 629 0.396 0.577

AW 829 0.667 0.577

Minimum Free Area m²

TABLE 1

Page 7

THIS TYPE OF

INSTALLATION

SHOULD BE AVOIDED

INCORRECT DRAINAGE

FOR CONDENSATE

CORRECT DRAINAGE

FOR CONDENSATE ELBOW

'U' TRAP

ADEQUAT E FALL

FIGURE 3

3. PLUMBING

a. Calorex '29' range Heat Pumps have water inlet/outlet connections as follows:

All models have 1½ " BSP parallel, male threads.

The machine is supplied with bungs fitted in the water connection fittings. These need to be removed before

the unit is installed. See Section 4.

b. 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 Heat Pump should be connected between the filter and the other

heater. (See figure 4).

c. Suitable breakable couplings should be installed local to heat pump.

d. If the heat pump is installed at a lower level than pool water then isolation valves should be fitted.

e. Drain valve or plug should be fitted to the lower pipe to facilitate drain down in 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 the condensation from the evaporator fins. This

should be run away to waste via ¾" domestic waste piping. It is therefore necessary to ensure that the

Calorex unit is placed on a level plinth so that the condensate water can run away with adequate fall to

waste ie.½" per foot min and must incorporate a 'u' trap as to not overflow the edges of the drip-tray inside

the machine. See figure 3.

Page 8

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 to use.

i. 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).

j. All pipework must be adequately supported with allowance for 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 the breakable connections to avoid any stresses on to the unit connections.

IMPORTANT

1. All Pool Purifying Devices and Chemical Injection Systems to be fitted down stream of heat pump

unless 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

metal components.

2. Water quality must be maintained as follows:

pH: 7.4 ± 0.4

Total Alkalinity: 80 - 120 ppm as CaCo3

Total Hardness: 100 - 300 ppm as CaCo3

Total dissolved solids: Max. 3000 ppm

Saline Water Maximum concentration 6% wt/wt

Chlorine - free Cl range 1.0 - 3.0 ppm

Ozone 0.8 - 1.0 ppm

Bromine 2 - 3 ppm

Baquacil 25 - 50 ppm

Aquamatic Ionic Purifier Maximum 2 ppm Copper

Tam Pure Purifier Maximum 2 ppm Copper

Sherwood Purifier Maximum 2 ppm Copper

3. Maximum pressure of water in heat pump circuit should not exceed 3.5kg/cm2(50 psi)

Page 9

KEY ISOLATION VALVE BREAKABLE COUPLING NON RETURN VALVE THREE WAY VALVE

NON

RETURN

VALVE CHEMICAL DOSING

SANITISER OR

DEVICE, IF FITTED

AUX HEATER

IF FITTED

FILTER

PUMP

TO WASTE FOR

WINTERISING

DRAIN DOWN

ANTI RETURN LOOP

TO BE INCORPORATED,

MINIMUM HEIGHT

100mm ABOVE HEAT PUMP

OULET PORT

(IF SANITISER FITTED)

100mm

CONDENSATE WATER

TO WASTE

SPARE PORT FOR

WINTERISING

FLUSHING

CONNECTION

TO WASTE

CALOREX

HEAT PUMP

POOL

RECOMMENDED PLUMBING SCHEMATIC

FIGURE 4

Page 10

6 MINS

FLOW LAMP ILLUMINATED,

ADEQUATE FLOW

FLOW LAMP NOT

ILLUMINATED,

INADEQUATE FLOW

POOL/SPA

PUMP

FILTER

WATER HEATING AFTER

6 MINUTE DELAY

SYMBOL CHART- ALL MACHINES

REMOVE AND DISPOSE

OF LABEL

4. DETERMINING WATER FLOW

Plumbing.

The machine must be plumbed in as shown, see diagrams below (a tear off label is attached to the machine on

delivery).

Adjust the flow rate until the flow light is illuminated, giving the correct flow rate. The “adequate flow” symbol

looks like this:

MACHINE SIDE

AW629 AND AW829 FLOW RATE 115 LITRES PER MINUTE

POOL

WATER IN POOL

WATER OUT

CONDENSATE

DRAIN

MACHINE LABEL

D436858 ISS 1

6 MINS

REMOVE BUNGS

BEFORE

INSTALLING

MACHINE

REMOVE BUNGS

BEFORE

INSTALLING

MACHINE

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