Calorex Pro-Pac Series Kurzanleitung

page 1

SD566252 ISSUE 48

Pro-Pac system

Pro-Pac 30/45/70/90/140M/MY

Owner installation manual (SD566252 issue 51)

2 SD566252 ISSUE 51

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.. 11

5.1 ELECTRICAL (MACHINE WIRING AND SUPPLY).......... 12

6.0 REGULAR PLANNED MAINTENANCE ........................... 27

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

8.0 HEAT PUMP MALFUNCTION........................................... 30

9.0 DATA SHEETS.................................................................... 33

10.0 INSTALLATION DRAWINGS........................................... 37

11.0 WINTERISATION PROCEDURE..................................... 47

11.1 START UP PROCEDURE AFTER WINTERISATION ..... 47

12.0 WARRANTY CONDITIONS............................................. 48

13.0 REFRIGERATION DIAGRAMS........................................ 49

14.0 MACHINE RECORD LOG................................................ 51

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)

SD566252 ISSUE 51

AIR/WATER HEAT PUMPS

IMPORTANT NOTE

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

All Calorex heat pumps are CE approved.

MODELS PRO-PAC 30/45/70/90/140

The Calorex Pro-Pac range of air/water heat pumps for

swimming pool applications consist of 5 models. Heat pumps

on is manual are designed for heating pool water and

spas wiin e range 7ºC to 40ºC. The titanium water heat

exchangers ﬁtted in ‘PPT’ Pro-Pacs are suitable for fresh and

salt water pools. Units wi e sux M are suitable for outdoor

pools operating in ambient temperatures above 10ºC, units

wi e sux MY are suitable for outdoor pools operating in

ambients -15ºC to 40ºC.

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 and a 6 minute timer is incorporated to

prevent compressor short cycling. 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.

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.

4 SD566252 ISSUE 51

PR0-PAC SYSTEM OWNER INSTALLATION MANUAL

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.

THE HEAT PUMP CYCLE

3. THE CONDENSER where it is surrounded by e pool water.

e 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 –

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 –

The Calorex Swimming pool heat pump provides ermodynamic

heating by means of a vapour compression cycle, (similar to at

employed in a conventional refrigerator), in addition to acting as an

active solar collector.

HOT GAS

COMPRESSOR

WATER

OUT

CONDENSED

REFRIGERANT

WATER

HIGH PRESSURE SIDE

HEAT

EXCHANGER

EXPANSION

VALVE

COLD LIQUID

REFRIGERANT

LOW PRESSURE SIDE

EVAPORATOR

COOL GAS

AMBIENT AIR

SD566252 ISSUE 51

INSTALLATION.

1. SITING

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 also to 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.

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.

6 SD566252 ISSUE 51

PR0-PAC SYSTEM OWNER INSTALLATION MANUAL

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)

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

2. AIR FLOW

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.

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.

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

incorporated into one common duct system.

3. 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.

SD566252 ISSUE 51

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. Drain valve or plug should be ﬁtted to lower pipe to facilitate drain down

in winter period.

5. The condensation from e evaporator ﬁns drains away rough holes in

e base of e unit. If desired, an optional factory ﬁtted driptray wi 1½"

sink ﬁtting can be ﬁtted to allow e condensate to drain via 1½" domestic

waste piping. In is case it is necessary to ensure at e Calorex Heat

Pump is placed on a level plin so at e condensate can run away

wi adequate fall to waste ie ½" per foot minimum. A U trap should also

be incorporated into e pipework.

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

- - Pro-Pac PPT30M/MY 2" UNION SOCKET

Pro-Pac 45 1½ BSPM Pro-Pac PPT45M/MY 2" UNION SOCKET

Pro-Pac 70 1½ BSPM Pro-Pac PPT70M/MY 3" BSPM

Pro-Pac 90 1½ BSPM Pro-Pac PPT90M/MY 3" BSPM

Pro-Pac 140 2" BSPM Pro-Pac PPT140M/MY 4" BSPM

3. PLUMBING

8 SD566252 ISSUE 51

PR0-PAC SYSTEM OWNER INSTALLATION MANUAL

IMPORTANT

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

down stream of heat pumps unless installation is as per ﬁlter dosing (see

ﬁgure 3).

This includes 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 - 120 ppm as CaCO3

Total Hardness 150 - 250 ppm as CaCO3

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 Commercial

Ozone 0.9 Max ppm

Bromine 2 - 5 ppm

Baquacil 25 - 50 ppm

Aquamatic Ionic Puriﬁer Max 2 ppm Copper

SD566252 ISSUE 51

POOL WATER SCHEMATIC

FILTER

FLOW SETTING

PRESSURE GAUGES

METHOD

PUMP

POOL

NON

RETURN

VALVE

SANITISER OR

CHEMICAL DOSING

POSITION AFTER

CALOREX

(STANDARD)

CALOREX

ENSURE POOL FILTRATION PUMP SELECTION ALLOWS FOR ALL SYSTEM RESISTANCE

OR LOOP

FLOW

SETTING

FLOW METER

METHOD

VALVE

ISOLATING

VALVE C

BYPASS VALVE

(LOCKING GATE VALVE TYPE)

AUX

HEATER

IF FITTED

FLOW METER METHOD (SEE FIG 3.)

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

Close e bypass valve until e ﬂow light at is positioned on e

heat pump console illuminates and en close it slightly more to allow

for ﬂow loss due to a dirty ﬁlter. Remove handle and lock oﬀ valve ‘C’.

Alternatively a water ﬂow meter can be installed. See data sheets for

ﬂow rates.

The Pro-Pac is ﬁtted wi a water ﬂow switch which inhibits e

operation of e machine when e minimum water ﬂow is inadequate.

Adjust e water ﬂow rate rough e heat pump until e green

Water Flow OK lamp on e machine console is illuminated. An

adequate water ﬂow rate has now been achieved.

Fig 3

4. DETERMINING WATER FLOW

10 SD566252 ISSUE 51

PR0-PAC SYSTEM OWNER INSTALLATION MANUAL

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