Calorex Pro-Pac Series Kurzanleitung

Pro-Pac system

Pro-Pac 30/45/70/90/140HC

Owner installation manual (SD566250 issue 35)

2 SD566250 ISSUE 35

PR0-PAC SYSTEM OWNER INSTALLATION MANUAL

CONTENTS

AIR/WATER HEAT PUMPS.........................................................4

THE HEAT PUMP CYCLE............................................................5

INSTALLATION ............................................................................6

1. SITING......................................................................................6

2. AIR FLOW................................................................................7

3. PLUMBING ..............................................................................8

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

5.0 ELECTROLYTIC CORROSION IN SWIMMING POOLS.. 13

5.1 ELECTRICAL (MACHINE WIRING AND SUPPLY).......... 14

ELECTRICAL CIRCUIT DIAGRAMS........................................ 17

REGULAR PLANNED MAINTENANCE.................................. 26

CONTROLS AND INDICATION LAMPS ................................. 27

CONTROLS AND INDICATION LAMPS ................................. 28

HEAT PUMP MALFUNCTION ................................................. 29

DATA SHEETS........................................................................... 32

INSTALLATION DRAWINGS.................................................... 34

WINTERISATION PROCEDURE .............................................. 46

START UP PROCEDURE AFTER WINTERISATION .............. 46

WARRANTY CONDITIONS...................................................... 47

REFRIGERATION DIAGRAM................................................... 48

MACHINE RECORD LOG......................................................... 49

HEALTH AND SAFETY WARNING

As e dehumidiﬁer embodies electrical and rotational equipment, ONLY competent persons

should carry out any work on is type of machine.

(SEE GUARANTEE)

SD566250 ISSUE 35

AIR/WATER HEAT PUMPS

MODELS Pro-Pac 30/45/70/90/140

The machines described wiin is manual are reverse cycle

air to water heat pumps, speciﬁcally designed for heating and

cooling swimming pool or potable water wi high water ﬂow

rates. The units are tropically rated and can operate in ambient

temperatures from 7°C to 50°C. Machines described as PPTs

are ﬁtted wi titanium water heat exchangers, titanium being

a highly corrosion resistant material.

Pro-Pac heater-chillers utilize non ozone depleting R134a

refrigerant, which is an ideal refrigerant for high ambient

temperature applications, and by correct selection will oﬀer

reliable all year round swimming pool water temperature

control or potable water cooling.

The units are fully packaged and should be sited outside in a

well ventilated area.

Oer features include integral safety devices to protect e

heat pump from internal and external faults. Indicator lamps

indicate operating mode. An adjustable ermostat controls

water temperature. Also a 6 minute timer is incorporated. A 12

hour delay timer is incorporated into all machines, which aer a

power interruption or from initial start will prevent e machine

compressor(s) from starting for a 12 hour period. This feature

is to protect e compressors from liquid pumping which can

cause internal compressor damage.

IMPORTANT NOTE

Danerm Ltd. is an ISO9001:2000 certiﬁed company.

All Calorex Heat Pumps are CE approved.

4 SD566250 ISSUE 35

PR0-PAC SYSTEM OWNER INSTALLATION MANUAL

HEALTH AND SAFETY WARNING

This appliance can be used by children from eight years and above and persons wi reduced

physical, sensory or mental capabilities or lack of experience and knowledge if ey have been

given supervision or instruction concerning e use of e appliance in a safe way and understand

e hazards involved. Children should not play wi e appliance. Cleaning and maintenance shall

not be made by children wiout supervision.

Disconnect from e mains supply and wait ree minutes before removing panels and

commencing work on is machine.

COLD LIQUID

REFRIGERANT

COOL GAS

AMBIENT

AIR

COMPRESSOR

EVAPORATOR

HIGH PRESSURE SIDE

CONDENSED

REFRIGERANT

WATER IN

HOT GAS

WATER OUT

HEAT

EXCHANGER

LOW PRESSURE SIDE

EXPANSION

VALVE

COLD LIQUID

REFRIGERANT

THE HEAT PUMP CYCLE

Coecient of Performance

The eciency of a heat pump is usually called its ‘Coecient of

Performance’ – (C.O.P.) which is simply a ratio of heat output to energy

input, bo being expressed in kW. Thus a heat pump absorbing 1 kW

of electricity, collecting 4 kW of energy from e air, and delivering

5 kW of heat to e pool water is said to have a C.O.P. of 5:1.

Naturally, is ratio will vary according to e temperature of e water

and e ambient air.

1. THE EVAPORATOR collects e heat from e

outside ambient air, pre-heated by e sun. In e

Calorex swimming pool heat pumps, high volumes of

outside air are drawn into e unit by e fan expelled

rough e evaporator ﬁns. The evaporator has liquid

refrigerant passing rough it which is at a considerably

lower temperature an e ambient air. Therefore

e air gives up its heat to e refrigerant which en

vaporizes. This preheated vapour now travels to –

2. THE COMPRESSOR where it is compressed and

upgraded to a much higher temperature. The hot

vapour now enters –

3. THE CONDENSER where it is surrounded by e

pool water. The heat is given up to e cooler pool

water and e now cold refrigerant returns to its former

liquid state but still under high pressure from e

compressor.

This pressure is released by passing e liquid rough –

4. THE EXPANSION DEVICE and from ere, now at normal

pressure, it is returned to e evaporator and e cycle starts

again.

Note at during e cooling cycle is process is reversed

SD566250 ISSUE 35



IMPORTANT NOTE

Li e unit into place using a fork li truck, or similar liing device, if liing e unit from

above spreader bars must be used to avoid any pressure on e sides of e unit or packing

materials.

DO NOT PUSH OR DRAG THE UNIT ALONG THE GROUND.

NOTE: These units are not recommended for plant room

installation.

1. Ensure heat pump on site is as ordered, i.e. model, electrical supply

and factory ﬁtted options

2. Inspect unit for damage, in particular inspect e evaporator (ﬁnned

side) to ensure at it is undamaged. (Minor indentations in e ﬁns

do not aﬀect performance). If severely damaged, endorse delivery

note in presence of e driver and send a recorded delivery letter to

transport company giving details.

3. Protect unit if installation is delayed.

4. Provide a ﬁrm level base capable of supporting operational weight

of unit; spread load on timber ﬂoor.

5. Ensure water cannot collect under unit - recommend units are

installed on plin100mm above ﬁnished ﬂoor level and to also aid

condensate drainage.

6. Allow adequate clearance to service panels on unit; recommend

500mm minimum (see installation drawings).

7. All Calorex heat pumps are by design as quiet as is practical,

however due consideration should be given to siting in order to

fully exploit is feature, i.e. ensure at e inlet and outlet grilles

face away from occupied premises.

8. Ensure loose debris such as leaves, grass cuttings, etc will not block

air inlet ﬁlters or grilles.

9. Consider protection from extreme weaer conditions.

INSTALLATION

1. SITING

6 SD566250 ISSUE 35

PR0-PAC SYSTEM OWNER INSTALLATION MANUAL

2. AIR FLOW

Due consideration must be given to air ﬂow, ie do not obstruct

inlet or outlet and ensure discharge air cannot recirculate to inlet

(see ﬁgures 1 and 2)

TABLE 1

Required Free Areas to provide air ﬂow to and from heat pumps

when installed on an enclosed area or where required to pass

rough a wall etc.

Free area is e available area rough which air can pass rough

a grille or louvres.

Grill or apertures MUST comply wi ﬁgures (see Table 1)

< 3 m

CANOPY OR OBSTRUCTION

TOO CLOSE

> 3 m

TYPICAL OUTSIDE INSTALLATION

FIGURE 1 FIGURE 2

TYPICAL INSIDE OR PLANT ROOM INSTALLATION

(NOT RECOMMENDED FOR LONG DUCT RUNS).

THE PLANT ROOM IS NOT TO BE USED AS AN

OCCUPIED SPACE.

ADEQUATE

DUCTING

ADEQUATE

DUCTING

PRO-PAC

90/140

PRO-PAC

30/45/70



TABLE 1

MODEL Minimum Free Area m²

Inlet Discharge

Pro-Pac 30 0.59 0.25

Pro-Pac 45 0.98 0.42

Pro-Pac 70 1.19 0.52

Pro-Pac 90 1.731 0.84

Pro-Pac 140 2.138 1.04

1. Note: If multiple units are installed in an enclosed area en e

inlet free areas required for each unit can be added togeer to

form one inlet aperture.

BUT discharge from each unit must be kept separate and must not be

incorporated into one common duct system.

2. If e unit is installed wiin a plantroom, connected to

ductwork, Danerm Ltd. can supply e unit wi an uprated

fan motor. Please consult Danerm Ltd. before ordering e

unit.

3. If e unit is installed in a plant room, e room should only be

accessible to auorised persons who are aquainted wi e

operation of e equipment and relevant safety precautions.

SD566250 ISSUE 35

3. PLUMBING

The Calorex pool heat pump must be connected aer e ﬁlter in e

return pipe to e pool. If an existing heater is being retained, en e

Calorex should be connected between e ﬁlter and e oer heater.

(See Figures 3 & 4).

1. Calorex heat pumps have water inlet/outlet connections as follows:

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

3. If heat pump installed at lower level an pool water en isolation

valves should be ﬁtted

4. A drain valve or plug should be ﬁtted to lower pipe to facilitate drain

down in winter period.

5. The condensate drain at e base of e unit collects e

condensation from e evaporator ﬁns.This should be run away to

waste via 1½" domestic waste piping. It is erefore necessary to

ensure at e Calorex Heat Pump is placed on a level plin so

at e condensate later can run away and not overﬂow e edges

of e drip-tray inside e machine.

6. When e pipework installation is complete e pool pump should

be switched on and e system tested for leaks. Also check

e ﬁlter gauge to see at ere is not an excessive increase in

back pressure. If everying is en working normally e water

circulating system is ready to use.

7. Water circuit to and from unit to be capable of maintaining wiin

speciﬁed limits e rate of ﬂow required by heat pump (see data

sheet).

8. All pipework must be adequately supported wi allowance for

expansion/contraction especially wi plastic pipework.

9. It is recommended at when installing water system e last

connections to be made in e system should be e breakable

couplings to avoid any stresses on to e unit connections.

CORRECT DRAINAGE

FOR CONDENSATE ELBOW

'U' TRAP

SUPPLIED BY

CONTRACTOR

ADEQUATE FALL



MODEL Water in/out

connection size

MODEL Water in/out

connection size BHC

Water in/out

connection size EHC

Pro-Pac PPT 30 2" UNION SOCKET 1½ BSPM

Pro-Pac 45 1½ BSPM Pro-Pac PPT 45 2" UNION SOCKET 2" BSPM

Pro-Pac 70 1½ BSPM Pro-Pac PPT 70 3" BSPM 2" BSPM

Pro-Pac 90 1½ BSPM Pro-Pac PPT 90 3" BSPM 3" BSPM

Pro-Pac 140 2" BSPM Pro-Pac PPT 140 4" BSPM 3" BSPM

8 SD566250 ISSUE 35

PR0-PAC SYSTEM OWNER INSTALLATION MANUAL

IMPORTANT

1. 1. All pool purifying devices and chemical injection systems to be

ﬁtted down stream of heat pumps unless installation is as per ﬁlter

dosing

(see ﬁgure 3).

This includes e 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:

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

pH 7.2-7.8

Total Alkalinity 80-120ppm as CaCO

Total Hardness 150-250ppm as CaCO

Total dissolved solids 1000 Max ppm

Saline Water (Titanium Condenser) 35,000 Max ppm

Saline Water (Cupro Nickel Condenser) 8,000 Max ppm

Chlorine -free Cl Range 1.0-2.0 ppm Domestic

Chlorine -free Cl Range 3.0-6.0 ppm Domestic

Ozone 0.9 Max ppm

Bromine 2-5 ppm

Bacquacil 25-50 ppm

Aquamatic Ionic Puriﬁer Max 2 ppm Copper

SD566250 ISSUE 35

4. DETERMINING WATER FLOW

a) Flow Meter Meod (see ﬁg 3.)

Ensure isolation valves ‘A’ and ‘B’ and bypass valve ‘C’ are fully open.

Slowly close down bypass valve ‘C’ until correct ﬂow rate (see data

sheets) is shown on e ﬂow meter. Remove handle and lock oﬀ valve

‘C’.

b) Diﬀerential Pressure Meod (see ﬁg 3).

By simply installing two ﬁlter pressure indicating gauges, one each on

e inlet and outlet of e heat pump, and a locking type gate bypass

valve in e bypass line, e ﬂow rate rough e heat pump can be

accurately determined by e diﬀerence in e readings of e gauges.

This pressure drop is proportional to ﬂow.

Flow rate should be set at e maximum diﬀerential wi a clean ﬁlter

if ﬁtted. is diﬀerential pressure will drop as e ﬁlter becomes dirty.

Provided e ﬁlter is cleaned before e minimum diﬀerential is reached

(which would normally be e case wi a well managed system) en

no problems should be encountered.

Setting up e diﬀerential

When e installation is complete, e procedure for setting e ﬂow

rate rough e heat pump using two gauges is as follows:

1. Wi e heat pump switched oﬀ, ensure isolation valves ‘A’, ‘B’

and bypass valve ‘C’ are fully open.

2. Switch on water circulating pump.

3. Note e water system pressure on bo gauges - ey should read

e same, but because of manufacturing tolerance ey may read

diﬀerent.

For example – wi a water system pressure of 5mhd e gauge

on e inlet may read 5 and e outlet gauge 5·5 erefore ere is

a STATIC ERROR DIFFERENCE of 0·5mhd.

4. Gradually close e bypass valve ‘C’ until ere is a diﬀerence in

pressure between e two gauges at is equal to e required

pressure drop (see data sheets) observing any static error on e

gauges before beginning is process.

5. Lock e bypass valve, or render it tamper proof, when correct

setting is achieved.

6. See data sheets for correct pool water pressure drop.

10 SD566250 ISSUE 35

PR0-PAC SYSTEM OWNER INSTALLATION MANUAL

Andere Handbücher für Pro-Pac Series

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