contents · a. calorex '20' range heat pumps have water inlet/outlet connections as...

Owner InstallationManual for

AW320, 620, 820, 1220, 1520AIR/WATER HEAT PUMPS

& AW834,1234,1534BH, AW1222HC, WA1222C

(SD331850 Issue 13)

CONTENTS

SWIMMING POOL .......................................................................................................................................... 1AIR/WATER HEAT PUMPS ............................................................................................................................. 1HOW THE HEAT PUMPS WORKS ................................................................................................................. 1INSTALLATION ............................................................................................................................................... 2SITING ............................................................................................................................................................ 2AIR FLOW ....................................................................................................................................................... 2PLUMBING...................................................................................................................................................... 3DETERMINING WATER FLOW ...................................................................................................................... 4ELECTRICAL ................................................................................................................................................... 8ELECTRICAL CIRCUIT DIAGRAMS ................................................................................................................ 11CONTROLS AND INDICATION LAMPS ...........................................................................................................15HEAT PUMP MALFUNCTION..........................................................................................................................16USER CHECK LIST ........................................................................................................................................16INSTALLATION DRAWINGS ............................................................................................................................19WINTERISING PROCEDURE..........................................................................................................................23START UP PROCEDURE AFTER WINTERISATION ........................................................................................23WARRANTY CONDITIONS .............................................................................................................................24

SWIMMING POOLAIR/WATER HEAT PUMPS

MODELS AW320, 620, 820,1220, 1520The Calorex '20' range of air/water heat pumps for swimming pool application consists of 5 models. The unitsAW1400, 1800 and 4000 are described in a separate manual. Heat pumps in this manual are designed for heatingpool waters and spas within the range of 10°C to 55°C with low water flow rate. The water heat exchanger issuitable for fresh water and salt water pools. Standard units are suitable for outdoor pools operating in ambients7°C to 40°C. Models 320, 620, 820, 1220 and 1520 can also be used for hot water generation up to 55°C.

All units have integral safety devices to protect heat pump from internal and external faults. Indicator lamps indi-cate operating mode. An adjustable thermostat controls water temperature. Also 6 min cycle time delay incorpo-rated.

HOW THE HEAT PUMP WORKSThe CALOREX Swimming Pool Heat Pumps pmvides thermodynamic heating by means of a vapour compressioncycle, (similar to that employed in a conventional refrigerator), in addition to operating as an active solar collector.

The EVAPORATOR collects the heat from the outside ambient air, pre-heated by the sun. In the Calorex swimmingpool heat pumps, high volumes of outside air are drawn into the unit by the fan expelled through the evaporatorfins. The evaporator has liquid refrigerant passing through it which is at a considerably lower temperature than theambient air. Therefore the air gives up its heat to the refrigerant which then vaporizes. This pre-heated vapour nowtravels to -

The COMPRESSOR where it is compressed and upgraded to a much higher temperature. The hot vapour nowenters -

The CONDENSER where it is surrounded by the pool water. the heat is given up to the cooler pool water and thenow cold 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 normal pressure, it is returned to the evaporator and the cyclestarts 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 ofheat 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.

Cooled Air Exhaust Compressor

ExpansionDevice

Outside Air Evaporator(Heat Collector)

Pool Filter

SwimmingPool

Condenser Heat Tranferedto Pool Water

Pool WaterPump

Pool Water

INSTALLATION

1. SITINGa 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 inpresence 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 on timber floor.

e Ensure water cannot collect under unit - recommend units are installed on plinths 100mm above finishedfloor level and to also aid condensate drainage.

f Allow adequate clearance to service panels on unit; recommend 500mm minimum (see installationdrawings).

g All Calorex heat pumps are by design as quiet as is practical, however due consideration should be givento siting in order to fully exploit this feature, i.e. orientate inlet/outlet 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.

2. AIR FLOWDue 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 figures 1 and 2)

Figure 1

TYPICAL OUTSIDE INSTALLATION

WALL, FENCE OR HEDGE

WRONG WRONG RIGHT

TYPICAL INSIDE OR PLANTROOM INSTALLATION

Figure 2

Grill or Apertures MUST comply with Figures (see Table 1)

TABLE 1

Required Free Areas to provide air flow to and from heat pumps when installed in an enclosed area orwhere required to pass air through a wall, etc.

Free area is the available area through which air can pass through a grille or louvres.

Note: If multiple units are installed in an enclosed area then the inlet free areas required for each unit can beadded 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.

TABLE 1

MODEL Minimum Free Area m²Inlet Discharge

AW 320 0·28 0·023AW 620 0·28 0·06AW 820 0·46 0·06AW 1220 0·46 0·07AW 1520 0·54 0·10

3. PLUMBINGa. Calorex '20' range Heat Pumps have water inlet/outlet connections as follows:

b. The Calorex Pool Heat Pump must be connected in bypass after the filter in the return pipe to the pool. Ifan existing heater is being retained, then the Calorex Heat Pump should be connected between the filterand the other heater.(See Figure 3 ).

All models ¾ " BSP parallel, male.(with ¾" BSPF x 1½" ABS male adaptors supplied loose)

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

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

e. Drain valve or plug should be fitted to lower pipe to facilitate drain down in winter period.

f. Connections on all models are by parallel female fittings sealed by silicone mastic these should be handtightened only, otherwise damage may result to the threads of plastic fittings.

g. The condensate drain at the base of the unit collects the condensation from the evaporator fins. Thisshould be run away to waste via ¾" domestic waste piping using connector supplied. It is thereforenecessary to ensure that the Calorex unit is placed on a level plinth so that the condensate water can runaway with adequate fall to waste ie.½" per foot min and must incorporate a 'u' trap as to not overflow theedges of the drip-tray inside the machine.

h. When the pipework installation is complete the pool pump should be switched on and the system testedfor leaks. Also check the filter gauge to see that there is not an excessive increase in back pressure. Ifeverything 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 requiredby heat pump (see data sheet).

j. All pipework must be adequately supported with allowance for expansion/contraction especially withplastic pipework.

k. It is recommended that when installing water systems the last connections to be made in the systemshould be the breakable connections to avoid any stresses on to the unit connections.

THIS TYPE OF INSTALLATION

SHOULD BE AVOIDED INCORRECT DRAINAGEFOR CONDENSATE

CORRECT DRAINAGEFOR CONDENSATE

ELBOW

'U' TRAP

ADEQUATE FALL

.

IMPORTANT

1. All Pool Purifying Devices and Chemical Injection Systems to be fitted down stream of heat pump unlessinstallation is as per Filter dosing (See Figure 3). This includes the practice of dosing chemicals direct intoSkimmer Basket, which results in concentrated corrosive liquids passing over metal components.

2. Water quality must be maintained as follows:

pH: 7.4 ± 0.4Total Alkalinity: 80 - 120 ppm as CaCo3Total Hardness: 100 - 500 ppm as CaCo3Total dissolved solids: Max. 3000 ppmSaline Water Maximum concentration 6% wt/wtChlorine - free Cl range 1.0 - 3.0 ppm

Superchlorination Max 30ppm for max 24 hrsOzone 0.8 - 1.0 ppmBromine 2 - 3 ppmBaquacil 25 - 50 ppmAquamatic Ionic Purifier Maximum 2 ppm CopperTam Pure Purifier Maximum 2 ppm CopperSherwood Purifier Maximum 2 ppm Copper

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

WINDOW

16 l/m

POOL WATER IN

POOL WATER OUT

MACHINE SIDE, MODEL AW32016 LITRES PER MINUTE

33 l/m

WINDOW

POOL WATER IN

POOL WATER OUT

33 LITRES PER MINUTE

MACHINE SIDE, MODELS AW620 TO AW1520/34

4. DETERMINING WATER FLOW (Models AW320 to AW1520/34)

Plumbing.

Machine must be plumbed in bypass, see diagrams below (Label on side of machine).Adjust gate valve to give required flow rate as indicated through window on side of machine.

DETERMINING WATER FLOW (Models AW1222,WA1222)

a) Flow Meter Method (see fig 3.)

Ensure isolation valves A' and 'B' and bypass valve 'C' are fully open. Slowly close down bypass valve 'C' untilcorrect flow rate (see data sheet page 18) is shown on the flow meter. Remove handle and lock off valve 'C'.

b) Differential Pressure Method (See fig 3).

By simply installing two filter pressure indicating gauges, one each on the inlet and outlet of the heat pump,and a locking type gate bypass valve in the bypass line, the flow rate through the heat pump can be accuratelydetermined by the difference in the readings of the gauges.This pressure drop is proportional to flow. Flow rateshould be set at the maximum differential with a clean filter if fitted. this differential pressure will drop as the filterbecomes dirty. Provided the filter is cleaned before the minimum differential is reached (which would normally bethe case with a well managed system) then no problems should be encountered.

Setting up the differential.When the installation is complete, the procedure for setting the flow rate through the heat pump using two gaugesis as follows:

1. With the heat pump switched off, ensure isolation valves 'A, 'B' and bypass valve 'C' are fully open.

2. Switch on water circulating pump.

3. Note the water System Pressure on both gauges - they should read the same, but because ofmanufacturing tolerance they may read different.

For example; with a water system pressure of 5mhd the gauge on the inlet may read 5 and the outletgauge 5.5 therefore there is a STATIC ERROR DIFFERENCE of 0.5mhd.

4. Gradually close the bypass valve 'C' until there is a difference in pressure between the two gauges. It willbe noted that the INLET gauge goes up in pressure.

Valve fully open After adjusting valvegauge pressure is: gauge pressure is:

INLET 5.0 6.7OUTLET 5.5 4.0DIFFERENCE 0.5 2.7

Therefore pressure difference is 2.7 + 0.5 = 3.2 metres hd

5. Lock the bypass valve, or render it tamper proof, when correct setting is acheived.

6. See data sheet (page 18) for correct pool water pressure drop.

POOL WATER SCHEMATIC

FILTER

PRESSURE GAUGES METHOD

PUMP

POOL

NON RETURN VALVE

SANITISER OR CHEMICAL DOSING POSITION AFTER CALOREX

FLOW SETTING

VALVE C

(Models AW1222, WA1222 Standard)

CALOREX

ENSURE POOL FILTRATION PUMP SELECTION ALLOWS FOR ALL SYSTEM RESISTANCE

OR LOOP

METHOD

FLOW SETTING FLOW METER

VALVEVALVEISOLATING

B

ISOLATING

A

BYPASS VALVE(LOCKING GATE VALVE TYPE)

AUX HEATER IF FITTED

POOL WATER SCHEMATIC (Models AW1222, WA1222 Filter Dosing)ENSURE POOL FILTRATION PUMP SELECTION ALLOWS FOR ALL SYSTEM RESISTANCE

METHODFLOW SETTINGFLOW METER

CALOREX

PUMP

POOL

NON RETURNVALVEOR LOOP

SANITISER ORCHEMICAL DOSINGPOSITIONBEFORE FILTER

FILTER

PRESSUREGAUGES METHODFLOW SETTING

BYPASS VALVE C(LOCKING GATE VALVE TYPE)

VALVEISOLATING

B

NON RETURNVALVEOR LOOP

AUX HEATERIF FITTED

VALVEISOLATING

A

6. ELECTRICAL (MACHINE WIRING AND SUPPLY) SEE FIG. 4,5,6 and 7 FOR PREFERRED METHODUse of the Calorex Energy Management Controller will enable greater savings to be made because the circulatingpump need only run when required and this can be at a time preferred by the Customer, i.e. in the Economy 7period.

All electrical work to be carried out in accordance with l.E.E. standards, latest issue, or local codes of practice asapplicable

Protected supply to incorporate fuses or motor type circuit breakers (Type GU, FAZC) to specified rating, (seeData Sheet). H.R.C. fuses are recommended. An isolator must be fitted within 2m and in sight of machine.†

All units must be correctly earthed-grounded. An earth leakage trip of the Current operating type (100mA) isrecommended 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 perform-ance or warranty terms:

Minimum MaximumVoltageSingle phase machines 207v 253vThree-phase machines 360v 440vCycle frequency 47.5Hz 52.5Hz

N.B. This voltage must be available at the heat pump whilst running.

† Note the isolator must have a minimum of 3mm air gap when turned off.

L

N

INTERLOCK

SOFT START

5

6

9

10

MANAGEMENTENERGYCONTROLLER

SOFTSTART

CONTROLLERMANAGEMENTENERGY

INTERLOCK

10

9 6

5

N

L3

L2

L1

1 PHASE 230v ~ 1N 50Hz

3 PHASE 400v ~ 3N 50Hz

ELECTRIC BOXMAINS IN

MAINS INELECTRIC BOX

MAINS INAT SIDE

ELECTRIC BOX ACCESS

REMOVE THE 8 SCREWS FROMTOP COVER AND LIFT OFF

LOCATION OF ELECTRICAL SUPPLY CONNECTIONSIN CALOREX HEAT PUMP

Fig. 4

L1

L2

L3

N

5

6

9

10

L

N

5

6

9

10

SOFT START

INTERLOCK

CALOREXHEAT PUMPSINGLE PHASE

ENERGY MANAGEMENTCONTROLLER

N L

3 4 5 6 7 8 9 10

L

N

SINGLEPHASE13AMP SUPPLY 230vFUSEDTO SUITWATERPUMP

N L

CALOREX ENERGYMANAGEMENT CONTROLLERAVAILABLE FROMCALOREX DISTRIBUTOR

SWITCHED FUSE ISOLATOR WITHIN 2m OF HEAT PUMP AND SIZED IN ACCORDANCE WITH DATA SHEET

WATER PUMPMAXIMIUM 3/4HPSINGLE PHASE

L1

L2

L3

N

5

6

9

10

L

N

5

6

9

10

N L

3 4

5 6

7 8 9 10

L

N

N L

CALOR EXENERGYMANAGEMENT CONTROLLERAVAILABLE FROMCALOREX DISTRIBUTOR

SINGLE PHASESUPPLY TO SUITCAPACITY OFWATER PUMP

L N

L N L

N L

4 POLE N/O STARTER WITHOVERLOAD AND 230v 50Hz COILRATED TO SUIT WATER PUMP

RECOMMENDED ELECTRICAL INSTALLATION FOR CALOREX HEAT PUMP (1Ø or 3Ø)WITH SINGLE PHASE WATER PUMP OF MAXIMUM ¾ H.P. AND

ENERGY MANAGEMENT CONTROLLER

Fig. 5

RECOMMENDED ELECTRICAL INSTALLATION FOR CALOREX HEAT PUMP (1Ø or 3Ø)WITH SINGLE PHASE WATER PUMP LARGER THAN ¾ H.P. AND


Fig. 6

INTERLOCK


SOFT START

CALOREXHEATPUMPTHREE PHASE

SINGLEPHASE13AMP SUPPLY 230vFUSEDTO SUITWATERPUMP


INTERLOCK


INTERLOCK


SOFT STARTSOFT START

CALOREXHEAT PUMPSINGLE PHASE

WATER PUMPMAXIMIUM 3/4HPSINGLE PHASE

CALOREXHEATPUMPTHREE PHASE

L1

L2

L3

N

5

6

9

10

SOFT START

INTERLOCK

CALOREX HEAT PUMP

THREE PHASE


L

N

5

6

9

10

SOFT START

INTERLOCK CALOREX HEAT PUMP

SINGLE PHASE


N L

3 4

5 6

7 8 9 10

L1

L2

SINGLE PHASE 13 AMP SUPPLY 230v FUSED AT 1 AMP

N L

CALOREX ENERGY MANAGEMENT CONTROLLER AVAILABLE FROM CALOREX DISTRIBUTOR


WATER PUMP THREE PHASE

THREE PHASE SUPPLY TO SUIT CAPACITY OF WATER PUMP L3 L1

L3 L2 L

4 POLE N/O STARTER WITH OVERLOAD AND 230v 50Hz COIL RATED TO SUIT WATER PUMP

L1

L3

L2

N

L1

L2

L3

N

5

6

9

10

SOFT START

INTERLOCK

CALOREX HEAT PUMP

THREE PHASE

L

N

5

6

9

10

SOFT START


SINGLE PHASE

L

N

SINGLE PHASE 13 AMP SUPPLY 230v FUSED TO SUIT WATER PUMP

N L


WATER PUMP MAXIMIUM 3/4 HP SINGLE PHASE

RECOMMENDED ELECTRICAL INSTALLATION FOR CALOREX HEAT PUMP (1Ø or 3Ø)WITH THREE PHASE WATER PUMP AND ENERGY MANAGEMENT CONTROLLER

Fig. 7

RECOMMENDED ELECTRICAL INSTALLATION FOR CALOREX HEAT PUMP (1Ø or 3Ø)WITH SINGLE PHASE WATER PUMP OF MAXIMUM ¾ H. P

Fig. 8

(NOTE: Method shown in Fig 9. is a preferred system due to encoporated starter and interlock)

INTERLOCK RELAY230v 50Hz 15 AMP N/O

L1

L2

L3

N

5

6

9

10

SOFT START

INTERLOCK

CALOREX HEAT PUMP

THREE PHASE

L

N

5

6

9

10

SOFT START


SINGLE PHASE

L

N

N L


WATER PUMP MORE THAN 3/4 HP SINGLE PHASE

SINGLE PHASE SUPPLY TO SUIT CAPACITY OF WATER PUMP

L N

L N L

N L


N

L1

L2

L3

N

5

6

9

10

SOFT START

INTERLOCK

CALOREX HEAT PUMP

THREE PHASE

L1

N

5

6

9

10

SOFT START


SINGLE PHASE

L1

L2

N L

SWITCHED FUSE ISOLATED WITHIN 2m OF HEAT PUMP AND SIZED IN ACCORDANCE WITH DATA SHEET

WATER PUMP THREE PHASE

THREE PHASE SUPPLY TO SUIT CAPACITY OF WATER PUMP

L3 L3

L3 L2 L


L1

L3

L2

N

RECOMMENDED ELECTRICAL INSTALLATION FOR CALOREX HEAT PUMP(1Ø or 3Ø)WITH SINGLE PHASE WATER PUMP OF LARGER THAN ¾ H.P.

Fig. 9

RECOMMENDED ELECTRICAL INSTALLATION FOR CALOREX HEAT PUMP(1Ø or 3Ø)WITH THREE PHASE WATER PUMP

Fig. 10

ELECTRICAL CIRCUIT DIAGRAM

ELECTRICAL CIRCUIT DIAGRAM

AW320, 620, 820, 1220 AM. AW834, 1234AH SINGLE PHASE (230v ~ 1 N 50Hz)

AW 620, 820, 1220 BM. AW834, 1234BH THREE PHASE ( 400v ~ 3 N 50Hz)

CO

MPR

ESSOR

C

S(A)

R(P)

DELAY

TIM

ER

HP SW

ITCH

CO

NTRO

L FUSE

FAULT LIG

HT

MAINS LIG

HT

RUN C

AP

START C

AP

DEFRO

ST

FAN

SOFT

START

LIVE

CO

NTACTO

R

SOFT

START

THERMAL

OVER

LOAD

& FAULT LIG

HT IF FITTED

RELAY/HAR

D

IF FITTED

IF FITTED

LP SW

ITCH

INTERLO

CK

TERM

INALS 5 6

DEFR

OST

STAT LIG

HT

FEED TER

MINALS

SMAR

T CLO

CK

9

10

N L

TERMINAL

BLOCK

CR

ANKCASE HEATER

(IF FITTED)

HOUR

SR

UN METER

IF FITTEDSENSO

R

462

111

10PO

OL STAT

CO

MPR

ESSOR

C

S R

DELAY

TIM

ER

HP SW

ITCH

CO

NTRO

L FUSE

FAULT LIG

HT MAINS LIG

HT

POO

L STAT

DEFR

OST

FAN

SOFT

START

L1 NEUTR

AL

CO

NTACTO

R

SOFT STAR

T THER

MAL

OVER

LOAD

& FAULT LIG

HT

IF FITTED

IF FITTED

LP SW

ITCH

INTERLOC

K TERM

INALS 5 6

DEFR

OST

STAT LIG

HT

SMART C

LOCK

FEED TERM

INALS

9

10

N L

TERM

INAL BLO

CK

L2 L3

CRANKCASE

HEATER

(IF FITTED)

FAN CAPAC

ITOR

HOUR

SR

UN METER

IF FITTEDSEN

SOR

462

111

10

WATER

PRESSURE SWITC

H(IF FITTED

)

WATER

PRESSU

RE SWITC

H(IF FITTED)

ELECTRICAL CIRCUIT DIAGRAM AW1520BM/1534BH THREE PHASE (400v ~ 3 N 50Hz)

CO

MPR

ESSOR

C

S R

DELAY

TIMER

HP

SWITC

H

CO

NTR

OL FU

SE

FAULT

LIGH

T MAIN

S LIGH

T

DEFR

OST

FAN

SOFT

START

L1 N

EUTR

AL

CO

NTAC

TOR

SOFT STAR

T TH

ERM

AL O

VERLO

AD

& FAULT

LIGH

T

IF FITTED

IF FITTED

LP SW

ITCH

INTER

LOC

K TER

MIN

ALS

5 6

DEFR

OST

STAT LIG

HT

SMAR

T CLO

CK

FEED TER

MIN

ALS

9

10

N L

TERM

INAL

BLOC

K

L2 L3

CR

ANKC

ASE HEATER

(IF FITTED

)

CO

NTAC

TOR

U1

V1

W1

HO

UR

SR

UN

METER

IF FITTEDSEN

SOR

462

111

10PO

OL STAT

CO

MP

RESSO

R

HP

SWITC

H

CO

NTR

OL FU

SE

MAIN

S SWITC

H/LIG

HT

REVER

SING

VALVE

INTER

LOC

K TER

MIN

ALS

SMAR

T C

LOC

K

NE

UTR

AL

CO

NTAC

TOR

SOFT

START

THER

MAL

OVER

LOAD

& FAU

LT LIG

HT

L1

CR

ANKC

ASE

FEED

TERM

INALS

5 6 9

10

N

L

FAN

FAN

CAP

LP SW

ITCH

DEFR

OST

STAT D

EFRO

ST LIGH

T

3 2

6 5

1 4

A B

7

1 4

SHU

T OFF

VALVE

A B 7

4

9

6

PR

ESSUR

E LIM

IT VALVE

HEATER

CO

MPR

ESSOR

AU

X N/O

EVAP PRESSU

RE

LIMIT SW

ITCH

RELAY

2

RELAY

1

CH

ILL LIMIT

LP SWITC

H

DELAY

TIMER

B A

POO

L/WATER

2 STAG

E STAT

RU

N

CAP

RELAY/H

ARD

STAR

T CAP

C

S R

9

3 6 FAU

LT LIG

HT

SOFT STAR

T IF FITTED

ELECTRICAL CIRCUIT DIAGRAMAW1222AHC SINGLE PHASE (230v ~ 1 N 50Hz)

(CH

ILL LIMIT FAU

LT)

(IF FITTED)

CO

MPR

ESSO

R

HP

SWITC

H

CO

NTR

OL FU

SE

MAIN

S SWITC

H/LIG

HT

REVER

SING

VALVE

INTE

RLO

CK

TERM

INALS

SMAR

T C

LOC

K

CO

NTAC

TOR

SOFT

START

THER

MAL

OVER

LOAD

& FAU

LT LIG

HT

CR

ANKC

ASE

FEED

TERM

INALS

5 6 9

10

N

L

FAN

FAN

CAP

LP SW

ITCH

DEFR

OST

STAT

DEFR

OST

LIGH

T

3 2

6 5

1 4

A B

7

1 4

SHU

T O

FF VALVE

A B 7

4

9

6

PRESSU

RE

LIMIT

VALVE

HEATER

CO

MPR

ESSOR

AU

X N/O

EVAP PR

ESSUR

E LIM

IT SWITC

H

RELAY

2

RELAY

1

CH

ILL LIMIT

LP SW

ITCH

DELAY

TIMER

B A

PO

OL/W

ATER

2 STAGE

STAT

R

S C

9

3 6 FAU

LT LIG

HT

SOFT

START

IF FITTED

ELECTRICAL CIRCUIT DIAGRAMAW1222BHC THREE PHASE (400v ~ 3 N 50Hz)

L1L2

L3N

EUTR

AL

(CH

ILL LIMIT FAU

LT)

(IF FITTED)

CO

MPR

ESSOR

C

S R

DELAY

TIMER

HP

SWITC

H

CO

NTR

OL FU

SE

FAULT

LIGH

T

POO

L STAT

RU

N C

AP

INTER

LOC

K TER

MIN

ALS

SOFT

START

CO

NTAC

TOR

SOFT STAR

T TH

ERM

AL O

VERLO

AD

& FAU

LT LAM

P

IF FITTED

SM

ART C

LOC

K FEED

TERM

INALS

5 6 9

10

IF FITTED

N L

CH

ILL LIMIT

FAULT

DE

FRO

ST

CH

ILL LIM

ITLP SW

ITCH

FAN M

OTO

R

EVAP PRESSU

RE

PRESSU

RE LIM

IT

FAN C

AP

MAIN

S

CR

ANKC

ASE H

EATER

SWITC

H/LIG

HT

LIGH

T

LIMIT SW

ITCH

C

OM

PRESSO

R

AUX N

/O

VALVE

ELECTRICAL CIRCUIT DIAGRAMWA1222AC SINGLE PHASE (230v ~ 1 N 50Hv)

L1N

EUTR

AL

(IF FITTED)

CO

MPR

ESSOR

C

S R

DELAY

TIMER

HP

SWITC

H

CO

NTR

OL FU

SE

FAULT

LAMP

POO

L STAT

INTER

LOC

K

TERM

INALS

SOFT STAR

T IF FITTED

C

ON

TACTO

R

SOFT STAR

T TH

ERM

AL O

VERLO

AD

& FAULT

LAMP

SMAR

T CLO

CK

FEED TER

MIN

ALS

5 6 9

10

IF FITTED

N L

CH

ILL LIMIT

FAULT

DEFR

OST

CH

ILL LIMIT

LP SWITC

H

FAN M

OTO

R

EVAP PRESSU

RE

PRESSU

RE LIM

IT

FAN C

AP

MAIN

S

CR

ANKC

ASE H

EATER

SWITC

H/LIG

HT

LIGH

T

LIMIT SW

ITCH

C

OM

PRESSO

R

AUX N

/O

VALVE

ELECTRICAL CIRCUIT DIAGRAMWA1222BC THREE PHASE (400v ~ 3 N 50Hv)

L1L2

L3N

EUTR

AL

(IF FITTED)

CONTROLS AND INDICATION LAMPS

THERMOSTATAdjustable digital thermostat controls pool water temperature at required level.Press and release key ‘P’ to display required temperature, to alter required temperature, press up or downsymbols. After 5 seconds display will revert to actual water temperature.OrAdjustable dial thermostat controls & maintains water temperature at required level (red pointer). The black pointerindicates actual water temperature.

INDICATOR LAMPS "AW" POOL HEATERS

MAINS RED Electrical supply onFAULT AMBER Internal or external fault conditionDEFROST WHITE Defrost Mode

INDICATOR LAMPS "AW" HEATER CHILLER

MAINS (SWITCH) RED Electrical supply on.Also includes ON/OFF rocker switch.

FAULT AMBER Internal or external fault conditionDEFROST WHITE Defrost Mode on water heating

Chill Limit Fault on water cooling

INDICATOR LAMPS "WA" CHILLER

MAINS (SWITCH) RED Electrical supply on.Also includes ON/OFF rocker switch.

FAULT AMBER Internal or external fault conditionDEFROST WHITE Chill Limit Fault on water cooling

HEAT PUMP MALFUNCTION

WARNING: Isolate machine electrically before entering machine 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.

If in doubt or if advice required contact Calorex Service Department.

Telephone (01621) 857171 or 856611

USER CHECK LIST

PMAL NOITCA

ETAREPOTONSEODTINU

SNIAM DER FFO lanretxe-ylppussniamkcehC

TLUAF REBMA FFO .cterotalosi-sesuf

TSORFED ETIHW FFO

SNIAM DER NO pmalsniamnohctiwsFFO/NOtinukcehC

TLUAF REBMA FFO .)ylnoC2221AW,CH2221WA(ylnonoylppussniamnospmaL

TSORFED ETIHW FFO setunim51retfafiesuflortnoclanretnikcehC.gnittestatsomrehtkcehCnurtonseodnaf

SNIAM DER NO .detcirtsertoneraswolfriadnaretawkcehC

TLUAF REBMA NO .dettiffitratStfoSnotuOtuclamrehtkcehC

TSORFED ETIHW FFO teserdnasehctiwstuotuc)C2221AWCH2221WAnoPLdna(PHkcehCerotserot.ctepmupretawkcehC.)tatsomrehtelosnocevobanottubder(

.enihcamhguorhtwolfretaw

FFOROSSERPMOCNONAF

SNIAM DER NO erutarepmetriatahtkcehc)edomgnitaeh(tsorfednotinU

TLUAF REBMA FFO )C2221WAton(C°7wolebtonsi

TSORFED ETIHW NO kcehC.)ylnoC2221AW-CH2221WAedomgnilooc(timilllihcnoffotinU.enihcamhguorhtwolfretawerotserot.ctepmupretaw

YLTNETTIMRETNISETAREPOTINU

SNIAM DER NO .detcirtsertoneraswolfriadnaretawkcehC

TLUAF REBMA FFO/NO etauqedasiylppuslacirtceletahtdna

TSORFED ETIHW FFO

For Accurate Application Sizing Consult CALOREX Heat Pumps Ltd.

NOTES:-1) Weight and dimensions nett2) Peformance design Iimitations Ambient = 10°C min, 40°C max Water = 10°C min, 55°C max3) Pool water to have correct balance, pH 7.4 ± 0.4 Free Chlorine 1.0 - 3.0 ppm4) Allow 500mm clearance to service panels5) Calorex reserve the nght to change or mod/v models wthout pnor notce

1mm WG = 9.8 Pa1m hd = 1.4 psi1L/min = 0.22 gall/min

HEAT PUMPS FOR OUTDOOR POOLSSUMMER SEASON

LEDOM stinU 023 026 028 0221 0251

RETAWLOOPOTTAEH

-:C°42RETAW,C°01TNEIBMA rhWk 6.3 3.7 5.9 6.21 8.51


LACITRCELE

-:DEMUSNOCREWOPLATOT



-:Nhp1).A.L.FxaM(YTICAPACYLPPUSNIM spma 6.6 9.11 7.51 6.12 N

-:Nhp3).A.L.FxaM(YTICAPACYLPPUSNIM spma A/N 0.7 8.7 7.9 5.11

-:Nhp1ESUFYLPPUS'XAM spma 01 91 72 53 A/N

-:Nhp3ESUFYLPPUS'XAM spma A/N 11 31 61 71

CTESWOLFRETAW

-:ETARWOLFRETAWLOOP nim/sertil 61 33 33 33 33

-:)wolFdetaR@(PORDERUSSERPRETAWLOOP dhsertem 75.4 1.2 2.3 9.3 6.4

-:RETAWLOOPERUSSERPGNIKROWXAM rab 5.3 5.3 5.3 5.3 5.3

-:SNOITCENNOCRETAWLOOP sehcni MPSB"4/3 MPSB"4/3 MPSB"4/3 MPSB"4/3 MPSB"4/3

-:SNOITCENNOCNIARDETASNEDNOC sehcni CiTSEMOD"4/3ETSAW

CiTSEMOD"4/3ETSAW

CiTSEMOD"4/3ETSAW

CiTSEMOD"4/3ETSAW

CiTSEMOD"-4/3ETSAW

ROSSERPMOC

-:DEMUSNOCREWOPLANIMON rhWk 8.0 1.2 8.2 4.3 0.4

-:Nhp1-.ARL spma 23 65 67 99 A/N

-:Nhp1-:ALR spma 42.5 1.8 3.11 1.51 A/N

-:Nhp1SPMATRATSTFOS spma 02 72 13 43 A/N

-:Nhp3-:ARL spma A/N 83 24 46 57

--:Nhp3-:ALR spma A/N 0.4 7.4 2.5 4.7

-:Nhp3SPMATRATSTFOS spma A/N 51 61 81 03

NAFNlAM

-:)rotaropaveteW.ellirgnoria@retemomenA(WOLFRIA m3 rh/ 538 0081 0052 0003 0593

-:ERUSSERPCITATSLANRETXEXAM gWmm 0 4 4 4 4

-:Nhp1-:ALF spma 63.0 2.2 2.2 5.3 A/N

-:Nhp3-ALF spma A/N A/N A/N A/N 5.1

ATADLARENEG

-:)dekcap-nU(HTDIW mm 718 028 0601 0601 0121

-:)dekcap-nU(HTPED mm 506 507 507 507 557

-:)dekcap-nU(THGIEH mm 046 067 708 708 708

-:)dekcap-nU(THGIEW gk 97 29 911 031 651

-:SERTEM3TASLEVELERUSSERPDNUOS Abd 55 55 75 95 26

-:)c704R(EGRAHCSAG gK 3.1 2.1 8.1 59.1 53.2

For Accurate Application Sizing Consult CALOREX Heat Pumps Ltd

NOTES:-1) Weight and dimensions nett2) Pertormance design limitations - Water heating mode - Ambient = 10°C min 50°C max 1534BH 12°C min 30°C max Water = 10°C min 50°C max 1534BH 15°C min 70°C max Water cooling mode - Ambient = 10°C min 50°C max (1534BH n/a) Water = 10°C min 35°C max (1534BH n/a)3) Pool water to have correct balance. pH 7 4 ± 0.4, Free Chlorine 1.0-3.0 ppm4) Allow 500mm clearance to senvice panels5) Calorex reserve the right to change or modify models without prior notice

1mm WG = 9.8 Pa1m hd = 1.4 psi1L/min = 0.22 gall/min

HEAT PUMPS FOR POOLS. SPECIALIST APPLICATIONSCHILLERS, HEATERS AND HEATER CHILLERS

LEDOM stinU CH2221 C2221 H438 H4321 HB4351

ROSSERPMOC

-:DEMUSNOCREWOPLANIMON rhWk 4.3 4.3 1.2 7.2 0.4

-:Nhpl-ARL spma 09 09 67 99 A/N

-:Nhpl-ALR spma 71 71 2.7 8.8 A/N

-:Nhp1SPMATRATSTFOS spma 33 33 13 43 A/N

-:Nhp3-ARL spma 93 93 24 46 57

-.ALR -:Nhp3 spma 8.5 8.5 2.3 5.3 0.5

-:Nhp3SPMATRATSTFOS spma 12 12 61 81 73

NAFNIAM

-:)rotaropaveyrd,ellirgnoria~retemomenA(WOLFRIA m3 rh/ 0023 0023 0562 0023 0004

-:ERUSSERPCITATSLANRETXEXAM gWmm 0 0 0 0 0

-:Nhpl-ALF spma 6.3 6.3 2.2 2.3 A/N

-:Nhp3-ALF spma A/N A/N A/N A/N 56.1

ECNAMROFREP

-:EDOMGNITAEHRETAW

-:C°03RETAW,C°01TNEIBMA rhWk 31 A/N 4·5 9·6 01

-:C°03RETAW,C°03TNEIBMA rhWk 71 A/N 3·9 9·11 3.71

-:EDOMGNILOOCRETAW

-:C°51RETAW,C°01TNEIBMA rhWk 2.21 2.21 A/N A/N A/N


CTESWOLFRETAW

-:ETARWOLFRETAWLOOP nim/sertil 33 33 33 33 33

-:)wolFdetaR@(PORDERUSSERPRETAWLOOP dhsertem 9.3 9.3 2.3 9.3 75.4

-:RETAWLOOPERUSSERPGNIKROWXAM rab 5.3 5.3 5.3 5.3 5.3

-:SNOITCENNOCRETAWLOOP sehcni MPSB"4/3 MPSB"4/3 MPSB"4/3 MPSB"4/3 MPSB"4/3

-:SNOITCENNOCNIARDETASNEDNOC sehcni CITSEMOD"4/3ETSAW

CITSEMOD"4/3ETSAW

CiTSEMOD"4/3ETSAW

CiTSEMOD"4/3ETSAW

CITSEMOD"4/3ETSAW

LACIRTCELE

-:DEMUSNOCREWOPLATOT

-:EDOMGNITAEHRETAW

-:C°03RETAW,C°01TNEIBMA rhWk 4.3 A/N 4.2 4.3 0.3

-:C°03RETAW,C°03TNEIBMA rhWk 8.3 A/N 5.2 6.3 5.3

-:EDOMGNILOOCRETAW



-:NhpI)ALFxaM(YTICAPACYLPPUSNIM spma 9.32 9.32 8.01 0.41 A/N

-:Nhp3)ALFsaM(YTICAPACYLPPUSNIM spma 5.01 5.01 0.6 4.7 51

-:Nhp1ESUFYLPPUSXAM spma 53 53 51 22 A/N

-:Nhp3ESUFYLPPUSXAM spma 61 61 01 21 52

SNOISNEMIDLACISYHP

-:)dekcap-nU(HTDIW mm 028 0601 0601 0601 0121

-:)dekcap-nU(HTPED mm 507 507 507 507 557

-:)dekcapnU(THGIEH mm 708 708 708 708 708

-:)dekcap-nU(THGIEW gk 751 051 911 031 651

-:SRETEM3TASLEVELERUSSERPDNUOS Abd 17 17 75 95 26

AW320DIMENSIONS mmWATER IN/OUT 3/4" BSPM STUBS ISSUE 3

605.

00

787.00

TOP VIEW

AREA REQUIRED FOR SERVICE ACCESS

AIR ON

AIR OFF

500.

00

500.

0031

0.00

101.

00

35.00

REAR VIEW


231.50 229.00

SIDE VIEW

120.

0015

6.00

164.00210.00

342.00

CONDENSATE

WATER IN

WATER OUT

FLOW GAUGEVIEWING WINDOW

116.0070.00596.0070.00

92.0

0

640.

00

FRONT VIEW

CONSOLE

HP RESETBUTTON

MAIN INAT SIDE

INSTALLATION DRAWINGS

AW620 DIMENSIONS mm ISSUE 7

AIR OFF

785

705

AIR ON

TOP VIEW

500


REAR VIEW

3/4 BSPM STUBS

258

145 287

192

35


500

1025

705

AIR OFF

AIR ON


500

TOP VIEW

35

258

225 287

192

3/4 BSPM STUBS


500

REAR VIEW

AW820/834 DIMENSIONS mm ISSUE 5

FRONT VIEW

SIDE VIEW

156 20

2

172213

305

WATER OUT

WATER IN

CONDENSATE

FLOW GAUGE VIEWING WINDOW

92

807

15670 79370

CONSOLE

HP RESET BUTTON

MAINS INAT SIDE

FRONT VIEW

760

1167059670

CONSOLE

92

MAINS IN AT SIDE

HP RESET BUTTON

CONDENSATE

202

156

172244.5

336.5

WATER IN

SIDE VIEW

WATER OUT

FLOW GAUGEVIEWING WINDOW

1025

705

AIR OFF

AIR ON


500

TOP VIEW

35

258

205 327

218

3/4 BSPM STUBS


500

REAR VIEW

AW1220/1234 DIMENSIONS mm ISSUE 7

755

500

1175

AIR OFF

TOP VIEW


AIR ON

500

288

335

207 393 35

REAR VIEW


3/4 BSPMSTUBS

AW1520/1534DIMENSIONS mmISSUE 3

92

807

15670 79370

CONSOLE

HP RESETBUTTON

MAINS IN AT SIDE

CONDENSATE 20

215

6

172244.5

336.5

WATER IN

SIDE VIEW

WATER OUT

FLOWGAUGEVIEWING WINDOW

386

294

172

156 20

2

WATER IN

WATER OUTCONDENSATE

FLOWGAUGEVIEWING WINDOW

SIDE VIEW

807

92

156

944

FRONT VIEW

HP RESETBUTTON

CONSOLE

70

70

MAINS IN AT SIDE

FRONT VIEW

1025

705

AIR OFF

AIR ON


500

TOP VIEW

35

256

202 332

290

3/4 BSPM STUBS


500

REAR VIEW

AW1222/WA1222DIMENSIONS mmISSUE 3

377

202

156

172244.5

336.5

CONDENSATE

WATER IN AW1222WATER OUT WA1222

SIDE VIEW

WATER OUTAW1222

WATER INWA1222

9280

7

15670 79370

MAINS IN

CONSOLE

FRONT VIEW

HP RESET BUTTON

LP RESET BUTTONNOT FITTED TOWA1222 MODELS

LP CHILL LIMITRESET BUTTON

WINTERISING PROCEDURE

WARNING. Isolate machine before opening! As the heat pump embodies electrical androtational equipment, it is recommended for your own safety that a competent person

carries out the following procedure

(Drain Down Procedure)ALL MODELS

Object

To provide frost protectionTo eliminate corrosion problemsTo 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 ofheat 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 hoseinto inlet connection - run for 10 minutes minimum; use spray nozzle if available.

6. Allow to drain - fit plastic bags secured by elastic bands over water connections.

7. Uncover electrical enclosure (see page 6 fig.4) and liberally spray interior of unit, with moisture-repellantaerosol WD40 or similar; reseal enclosure.

8. If heat pump located outside, protect from weather by covering with VENTILATED cover. Do not useplastic sheet as condensation can occur within unit.

N.B. If this procedure is not adopted and frost or corrosion damage results then the warranty will become invalid.

START UP PROCEDUREAFTER WINTERISATION

1. Replace covers (if not fitted).

2. Remove front grille -- using 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 any airin 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 daily to ensure pool water is at correct pH and has correct chemical balance. See Section 3Plumbing

WARRANTY CONDITIONS.The following exclusions apply to the Warranty given by Calorex Heat Pumps Ltd. No claims will be accepted if : -

1. The heat pump is incorrectly sized for the application.

2. The heat pump is installed in any way that is not in accordance with the current procedures as defined byCalorex Heat Pumps Ltd.

3. The heat pump has been worked upon or is adjusted by anyone other than a person authorised to do soby 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: 7.4 ± 0.4Total Alkalinity, as CaCo3 ppm 80 -120Total Hardness, as CaCo3 ppm 100-500Total Dissolved Solids: ppm MAX 3000Maximum Salt Content: wt/wt 6%Free Chlorine Range: ppm 1.0 - 3.0

Superchlorination: ppm MAX 30 for MAX 24hrsBromine: ppm 2-3Baquacil: ppm 25 - 50Ozone: ppm 0.8 - 1.0*Maximum Copper Content: ppm MAX 2*Aquamatic Ionic Purifier: ppm MAX 2*Tarn Pure Purifier: ppm MAX 2*Sherwood Purifier: ppm MAX 2

7. The heat pump has suffered frost damage.

8. The electrical supply is insufficient or in anyway incorrect

IF IN ANY DOUBT PLEASE ASKNote:- The Reply Paid Warranty Registration Card must be returned, to ensure that the correct warranty is given. Ifyou do not find a Registration Card with your Heat Pump please contact the Calorex Service Department giving yourname, address and serial number of your heat pump. A card will be sent to you for completion.

01621 857171 01621 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

contents · a. calorex '20' range heat pumps have water inlet/outlet connections as...

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